Chevrolet - Silverado 1500 2wd - Workshop Manual - 2007 - 2007

Page 21905 Memory Seat Module X4 (AN3) Page 11529 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 1002 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 6875 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 24731 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 464 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 10606 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 19312 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 8467 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 14891 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 22457 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13324 Tighten the bolt to 11 N.m (97 lb in). 6. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 9. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Diagrams Memory Positioning Module: Diagrams Power Seat Connector End Views Memory Seat Module X1 (AN3) Memory Seat Module X2 (AN3) Page 23221 The DIC displays the timer in the following format: XX: XX:XX: The first XX represents hours elapsed, the second XX represents minutes elapsed, and the third XX represents seconds elapsed. The maximum range of the timer is 99 hours, 59 minutes, and 59 seconds. After the maximum range is reached, the timer displays all zeros (00:00:00). Park Assist Menu The park assist menu is displayed in the DIC. The DIC displays the current state of the park assist until the IPC receives a message indicating otherwise. The DIC displays (- - -) when communication with park assist is lost. English/Metric The English/Metric mode is used to toggle between English and Metric units and can be accessed through the driver information center (DIC) Vehicle Info switch. Trip A/B The trip odometer A or B can be accessed through the DIC Trip/Fuel switch function. Language The driver information center (DIC) is capable of displaying in 8 languages * English * German * Italian * French * Spanish * Arabic * Chinese * Korean Page 4623 Important: Do not manually depress the retaining clip when installing the plastic cap. 6. Snap the plastic cap onto the quick connect fitting. 7. Ensure that the plastic cap is fully seated against the fitting. 8. Ensure that no gap is present between the cap and the fitting. 9. Inspect and fill the engine oil to the proper level. Diagrams Fuel Level Sensor: Diagrams Displays and Gages Connector End Views Fuel Pump and Sender Assembly - Front (Gas) Fuel Pump and Sender Assembly - Rear (Gas +LY6) Page 18747 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Crew Cab -10 Series) Page 21456 Disclaimer Page 21898 Outside Rearview Mirror References Page 17292 X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Page 2749 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Locations Torque Converter Clutch Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 14867 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 21188 Page 8428 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 24085 Turn Signal Switch: Diagrams Lighting Systems Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Page 19922 Page 12950 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 7627 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 11251 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Page 16457 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) to Headliner Harness (UE1/U3U/UVB) Page 8738 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 14284 26. Align the following during this procedure: * The CV joint boot (3) * The CV joint assembly (1) * The swage ring (2) 27. Install the top half of J 36652-1 or J 36652-2 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29. Insert the bolts into J 36652-1 or J 36652-2. Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half of the tool. 30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive shaft seal cover, if applicable. 32. Install the wheel drive shaft. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch Page 4573 Step 1 - Step 7 Page 3612 Step 1 - Step 7 Page 5621 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 6032 Vehicle Zoning Strategy Truck Zoning Diagrams Canister Purge Solenoid: Diagrams Engine Controls Connector End Views Evaporative Emission (EVAP) Canister Purge Solenoid Valve Page 2618 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 24522 4. Connect the other end of the jumper harness into the connector (1) at the windshield solvent heater module. 5. Ensure that the jumper harness and windshield solvent heater module wire harness are routed and secured properly. 6. For vehicles that previously had the 60 amp heated windshield washer fuse removed, retrieve the fuse from the glove compartment and reinstall the fuse. Important It may take up to 40 seconds for the heated washer fluid system to dispense heated fluid. 7. Verify the operation of the heated washer fluid system. Ensure the system dispenses heated fluid. Claim Information - GM, Saturn Canada Only Submit a Product Recall Claim with the information indicated below: Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information below: * The parts allowance should be the sum total of the current SSPO retailer net price plus 40% of all parts required for the repair. Customer Notification - For US and Canada General Motors notified customers of this recall on their vehicle in September 2008. Customer Notification - For Export Letters were sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Resonator Replacement Removal Procedure 1. Disconnect the positive crankcase ventilation (PCV) hose (1) from the air cleaner outlet resonator. 2. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 3. Loosen the air cleaner outlet resonator clamp (2) at the throttle body. 4. Remove the air cleaner outlet resonator from the throttle body and the MAF/IAT sensor. Installation Procedure Page 16192 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 12282 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 12390 Transmission Position Switch/Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft Position Switch Replacement Instruments/Audio - No Speaker Audio/Warning Chimes Audible Warning Device: All Technical Service Bulletins Instruments/Audio - No Speaker Audio/Warning Chimes Bulletin No.: 07-08-44-008 Date: April 18, 2007 TECHNICAL Subject: No Audio/No Sound Heard from Radio Speakers, Turn Signals, Hazard Signals and No Warning Chimes When a Door or Liftgate is Opened (Inspect/Seat C2 Audio Amplifier Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Speakers, Premium Audio w/Amplifier or Rear Stereo Audio (RPOs UQA, UQS or UK6) Condition Some customers may comment on one or all of the following conditions related to no audio/no sound: No sound from one or more of the radio speakers. No blinking sound heard form the turn signals or hazard signals when on. No audio warning chimes heard when a door or liftgate is opened. Cause The C2 Audio Amplifier Connector may become unseated at the amplifier. Correction Inspect/Seat the C2 Audio Amplifier Connector (16-way, Black Connector). Remove the radio, amplifier, and SIR fuses located in the Underhood Bussed Electrical Center (BEC). Gain access to the radio speaker amplifier. Refer to Radio Speaker Amplifier Replacement in SI. Page 8445 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 652 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4120 Junction Block - Left I/P, Bottom View Page 17366 X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) Page 23888 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 5234 Heater Core: Service and Repair Heater Core Replacement Heater Core Replacement Page 12606 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 7919 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Electrical - 'No Trailer Connected' Message On DIC Trailer Brake Control Module: Customer Interest Electrical - 'No Trailer Connected' Message On DIC TECHNICAL Bulletin No.: 09-05-22-004 Date: November 05, 2009 Subject: No "Trailer Connected" Message on Driver Information Center (DIC) at Startup When Trailer is Connected (Reprogram ITBCM) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Equipped with Integrated Trailer Brake (RPO JL1) Condition Some customers may comment that when they connect their trailer, with the engine off, and after they start the engine, the Trailer Connected message is not displayed on the DIC. With the engine running, if the trailer connector is cycled, the vehicle will detect the trailer and display Trailer Connected. This concern should only affect trailers equipped with trailer brakes on a single axle. Cause The trailer brake control system is only compatible with trailers equipped with electric trailer brakes. The system will not work or detect trailers equipped with any other types of brakes such as surge, air or electric-over-hydraulic trailer brake systems. When a trailer is connected, the Trailer Brake Control Module (TBCM) performs a test to determine if the trailer is equipped with electric trailer brakes. If the trailer wiring or electric trailer brake magnets have additional resistance (caused by poor connections, corrosion, improper splices, etc.), the TBCM may not be able to detect the trailer. Correction A revised calibration has been developed to address these issues. Reprogram the Integrated Trailer Brake Control Module (ITBCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Refer to Trailer Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 23784 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 12121 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 15382 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Important: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Page 1159 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Suspension - Multiple Noises From Front Of Vehicle Suspension Travel Bumper: All Technical Service Bulletins Suspension - Multiple Noises From Front Of Vehicle TECHNICAL Bulletin No.: 10-03-08-002A Date: November 03, 2010 Subject: Squeak/Creak/Rumble or Rattle Noise Coming from Front of Vehicle During Low Speed Maneuvers in Cold Ambient Temperatures (Enlarge Upper Inside Diameter (ID) of Strut Jounce Bumper) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado LD, Suburban LD, Tahoe 2007-2011 GMC Sierra LD, Sierra Denali, Yukon, Yukon XL LD, Yukon XL Denali Supercede: This bulletin is being revised to add the 2011 model year and clarify the text in the Subject, Condition, Cause and Correction. Please discard Corporate Bulletin Number 10-03-08-002 (Section - 03 Suspension). Condition Some customers may comment on a squeak, creak, rumble or rattle noise coming from the front of the vehicle or it may sound like it is coming through the front of the dash, during low speed maneuvers. The noise may be most noticeable in ambient temperatures of 0°C (32°F) or colder. The noise will most likely be heard during small to medium suspension travel such as in parking lot maneuvers, over small bumps, or when stopping. Cause This condition may be caused by the front strut jounce bumper inside diameter to the piston rod of the strut experiencing a slip/stick condition during certain cold ambient temperature conditions. Correction 1. Test drive the vehicle in the same range of ambient temperatures of 0°C (32°F) or colder and the same low speed maneuvers mentioned by the customer in order to verify the concern. 2. Using Chassis Ears, verify that the noise is most noticeable at the upper strut mount area. The concern may be on one or both sides of the vehicle. 3. By jouncing the vehicle, the noise or vibration can be isolated using a stethoscope, and may possibly be felt in the vicinity. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 5. Remove the LH and RH strut assemblies from the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 6. Disassemble the coil spring and top mount assembly from each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. Interior - Lint Accumulation On Ebony Colored Seats Arm Rest: Customer Interest Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 9232 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 12343 21. Remove the spacer plate support bolts (77). 22. Remove the spacer plate support (53). 23. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). Notice: Refer to Fastener Notice. 2. Install the spacer plate support (53) and bolts (77). Tighten the bolts to 10 N.m (89 lb in). Page 1000 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 23644 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 2234 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 5915 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Specifications Piston Ring: Specifications Piston Rings Piston Ring End Gap - First Compression Ring - Production ............................................................................................ 0.25-0.40 mm 0.010-0.016 in Piston Ring End Gap - Second Compression Ring - Production ....................................................................................... 0.38-0.58 mm 0.015-0.023 in Piston Ring End Gap - Oil Control Ring - Production ...................................................................................................... 0.25-0.76 mm 0.010-0.029 in Piston Ring End Gap - First Compression Ring - Service ................................................................................................. 0.25-0.50 mm 0.010-0.020 in Piston Ring End Gap - Second Compression Ring - Service ............................................................................................. 0.38-0.80 mm 0.015-0.031 in Piston Ring End Gap - Oil Control Ring - Service .................................................................................................... 0.005-0.090 mm 0.0002-0.0035 in Piston Ring to Groove Clearance - First Compression Ring - Production ................................................................. 0.030-0.070 mm 0.0012-0.0027 in Piston Ring to Groove Clearance - Second Compression Ring - Production ............................................................ 0.076-0.280 mm 0.0030-0.0110 in Piston Ring to Groove Clearance - Oil Control Ring - Production ............................................................................ 0.046-0.196 mm 0.0018-0.0077 in Piston Ring to Groove Clearance - First Compression Ring - Service ...................................................................... 0.030-0.085 mm 0.0012-0.0033 in Piston Ring to Groove Clearance - Second Compression Ring Service .................................................................. 0.030-0.085 mm 0.0012-0.0033 in Piston Ring to Groove Clearance - Oil Control Ring - Service ................................................................................. 0.076-0.200 mm 0.0030-0.0079 in Page 11562 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 7639 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 12984 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4769 pressure should stabilize and remain constant. 1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 3. Remove the J 37287 and CH-48027. 4. Operate the vehicle within the conditions of the customers concern while monitoring the fuel trim and O2 parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 5. If the fuel system components test normal, refer to Symptoms - Computers and Control Systems. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms Engine Controls Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Fuel Injector Replacement * Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Page 10215 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 11960 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 20887 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Page 6051 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2969 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 11728 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 13253 Fluid Pressure Sensor/Switch: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 2603 Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting * Ensure that the lifting equipment meets weight requirements and is in good working order. Always follow the lift manufacturer's instructions. * You may lift and support the front of the vehicle at the front suspension near the wheel assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle as possible. * Ensure that the vehicle is centered on the hoist before attempting to lift. * When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for the rear stabilizer bar. Stop Lamp Switch Replacement (Adjustable Pedal) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Adjustable Pedal) Stop Lamp Switch Replacement (Adjustable Pedal) Page 20229 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 222 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 11859 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 1489 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 17077 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Body - Chrome Outside Door Handle Loose/Cracked Front Door Exterior Handle: Customer Interest Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Page 8900 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 22043 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof Window Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. 2. Carefully remove the sunroof window weatherstrip from the perimeter of the sunroof window. Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window to the sunroof module assembly. 3. Ensure that the sunroof does not have any air or waterleaks. Page 8 Alarm Module: Service and Repair Theft Deterrent Module Replacement Page 20951 The latch and its backing plate have been removed on the above illustration to show the location for the lube. 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-002B Date: 060403 Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Page 17380 X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW/5X7/5Y0) to Right A-Pillar Harness (CF5/TRW/5X7/5Y0) X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness Page 16979 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 14742 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 516 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 2722 Throttle Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 6905 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 17370 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Harness (Gas) Page 20890 handle between the pawl and the tower where the gray pin enters through the spring and the pawl. 3. Cycle the handle at least 20 times to work the grease around the pin and to make sure that the squeak has been eliminated. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15099 Transmission Speed Sensor: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 22988 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 2254 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11240 Page 21853 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 16887 Junction Block - Left I/P, Label Junction Block - Left I/P, Device Usage Right I/P Junction Block Page 21344 Tighten the bolts to 22 N.m (16 lb ft). Install the center front seat. Refer to Center Seat Replacement in SI. Install the front seats. Refer to Front Seat Replacement in SI. Install the front seat belts to the seats. Refer to Seat Belt Retractor Pretensioner Replacement in SI. Install the front hinge pillar trim panels. Refer to Body Hinge Pillar Trim Panel Replacement in SI. Install the front door sill plates. Refer to Front Door Sill Plate Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3613 Step 8 - Step 13 Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 2909 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 13122 4. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Tighten the bolt to 11 N.m (97 lb in). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), Page 11373 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 11978 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 547 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 21095 Hood Stop: Service and Repair Hood Stop Bumper Bracket Replacement Hood Stop Bumper Bracket Replacement Page 12698 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 23955 Page 5761 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 10551 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 21515 Center Pillar Lower Garnish Molding Replacement Center Pillar Lower Garnish Molding Replacement Page 17541 Inspect how the IP branch to C202 is routed. Reroute the wiring as necessary to match the correct routing in the photo above. In order to route the IP harness branch correctly (behind the junction block-left I/P): Remove the cover from the junction block-left I/P, unseat the junction block from the bracket. Disconnect C202. Route the harness such that it lays between the goalposts of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. Make sure that the grey offset retaining clip (off of the IP branch going to C202) is seated into the hole in the dashmat or into the brown buddy clip (if present), securing the IP branch to the vehicle. If the harness is still in contact with a sharp edge or point of the park brake assembly, protect the harness by routing it away from the contact point and holding it there with tie straps, and/or covering the sharp edge with butyl tape. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1173 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test Circuit/System Verification Important: On the scan tool, the powertrain relay is referred to as the EC ignition relay. 1. Ignition ON, engine OFF, command the powertrain relay ON and OFF several times using the scan tool output control function. You should either hear or feel the relay click with each command. 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate on at least one test point of each fuse. ‹› If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data list. Circuit/System Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit and ground. ‹› If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 3. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 4. Verify that a test lamp illuminates between the relay coil B+ and ground. ‹› If the test lamp does not illuminate, test the relay coil B+ circuit for a short to ground or an open/high resistance. 5. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground or an open/high resistance. If the circuits test normal Page 22508 Heated Seat Element - Passenger Cushion Page 11217 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 7474 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 6387 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 9758 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 10835 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 6869 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 2220 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 15043 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 3976 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 4129 Junction Block - Left I/P X8 Page 10712 Fuel Filler Hose: Service and Repair Filler Tube Replacement (Extended Cab w/26 Gal Tank) Filler Tube Replacement (Extended Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Vehicle Lifting. 5. Remove the fuel tank fill pipe ground wire bolt. 6. Remove the fuel tank fill pipe ground wire anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire. Page 1500 Seat Adjuster Switch - Passenger (AG2 -AN3) Seat Adjuster Switch - Passenger (AN3) A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 110 Page 6378 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 6751 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 2431 Page 13478 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Page 210 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 24685 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 18696 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 2794 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 11092 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Locations Auxiliary Power Outlet: Locations Power Outlet Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 17402 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Important: * Always note the orientation of the relay. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Page 12833 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 21485 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9766 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 2500 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 5168 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 10842 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Diagrams Memory Positioning Module: Diagrams Power Seat Connector End Views Memory Seat Module X1 (AN3) Memory Seat Module X2 (AN3) Page 14031 Page 13489 Transmission Speed Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 11678 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 19719 Page 5807 View of the connector when released from the component. View of another type of Micro 64 connector. Page 23065 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 2141 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 435 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 6817 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: * The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. * Apply the park brake. * The engine must start in the park (P) or neutral (N) positions only. * Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 23215 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 7939 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 14048 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Page 9627 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 6306 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 3002 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 3191 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Driver Door Page 2857 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 3743 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Page 11198 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 7881 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Diagrams Canister Vent Valve: Diagrams Engine Controls Connector End Views Evaporative Emission (EVAP) Canister Vent Solenoid Valve Page 21889 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 6974 Throttle Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 2691 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 20934 Page 7389 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 21351 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Page 2205 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 19687 Disclaimer Page 3226 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1004 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 18703 2. Move the driver's seat to the full forward or rearward position. Carpet and cutout flap (2) shown with the driver's seat removed from the vehicle for illustration purposes only. Seat removal is NOT required to gain access to the acoustical pad (3). 3. Lift the cutout flap (2) in the carpet or vinyl to gain access to the acoustical pad (3) that covers the SDM. Seat removed for illustration purposes only. 4. Using your hand, tear away and remove the acoustical pad (3) that covers the SDM (4). Ensure that no acoustical pad remains over, or in contact with, the SDM (4). 5. Lower the carpet or vinyl cutout flap over SDM (4) and adjust the driver's seat to the customer-desired position. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. Page 5064 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6079 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 5744 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 4919 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 13678 Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 7. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Page 8088 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 5378 Page 12576 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2424 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 13014 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 13440 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Connect the internal wiring harness electrical connectors to the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) 23. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 24. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 16370 For vehicles repaired under warranty, use the table. Disclaimer Page 17369 X276 Inline Harness Connector End Views X276 Steering Column Harness to Inflatable Restraint Steering Wheel Module Coil (KA9) Page 5780 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 7402 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 12402 Transmission Speed Sensor: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Input and Output Speed Sensor (ISS/OSS) Page 8284 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 6409 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 16886 Fuse Block - I/P, Device Usage Left I/P Junction Block Page 14931 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 4043 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 14212 3. Install the axle shaft seal using the J 21128 (8.6 inch and 9.5 inch LD axles) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 9. Lower the vehicle. Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) Tools Required * J 8092 Universal Driver Handle-3/4 in - 10 * J 21128 Axle Pinion Oil Seal Installer * J 23690 Axle Shaft Bearing Installer * J 2619-01 Slide Hammer * J 44685 Rear Axle Seal and Bearing Remover Removal Procedure 1. Remove the axle shaft. 2. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (1) and the J 2619-01 (2). Installation Procedure Page 19630 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 12452 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 5842 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 7293 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 8391 Page 11556 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 23891 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 12171 Shift Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. Important: * When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall Page 16409 X207 Inline Harness Connector End Views X207 I/P Harness to I/P Harness (6J4) Page 6734 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Lighting - Turn Signals Have Increased Flash Rate Body Control Module: Customer Interest Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15090 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 17054 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 9841 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 1028 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 11676 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 8290 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Communication Interface Module Replacement (without RPO SLT) Central Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Page 22908 Technical Service Bulletin # 09-08-68-001 Date: 091114 Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required j 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the oil pressure sensor. Do not allow debris to enter the engine. 1. Disconnect the fuel pump/oil pressure sensor electrical connector (3). 2. Using J 41712, remove the fuel pump/oil pressure sensor. Page 20537 ^ Click on For Body Shops & Services link at the bottom of the page. ^ Click on GM Technical Repair Information ^ Click on Paint Shop tab. ^ Select the applicable downloadable link of the GM Approved Refinish Materials Guide. *In Canada the 2008 GM Approved Refinish Materials information is also available on the GM infoNET under the Service and Bodytab. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9281 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 10801 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 9815 Transmission Position Switch/Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft Position Switch Replacement Page 12675 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 11070 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2296 Page 23280 Page 12782 Tighten the bolt to 11 N.m (97 lb in). 6. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 9. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 6636 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 13011 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 9370 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Reluctor Ring Replacement Crankshaft Position Sensor Reluctor Ring Replacement Tools Required j 5590 Rear Pinion Bearing Race Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position (CKP) sensor reluctor ring. Installation Procedure Page 8337 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 11264 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 564 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 3028 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 9593 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 12780 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (367A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 15514 8. Depress and hold the retaining ring (2) with a small tool inserted into the access hole (1). 9. Remove the accumulator retainer ring (1) using a small hook shaped tool. 10. Release the C-clamp. 11. Remove the nut from the stud. 12. Remove the J 26889. 13. Remove the accumulator (2) and the O-ring seal (3). Installation Procedure Page 2690 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 9422 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 833 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 5526 7. Remove the exhaust manifold bolts and stud. 8. Remove the exhaust manifold and gaskets (1). Discard the gaskets. 9. Remove the exhaust manifold to catalytic converter seal (2). Discard the seal. Installation Procedure 1. Install a NEW exhaust manifold to catalytic converter seal (2) into the relief in the catalytic converter. 2. Place the exhaust manifold into position and install the manifold studs to the catalytic converter. 3. Place the NEW exhaust manifold gaskets (1) between the manifold and the cylinder head. Notice: Refer to Fastener Notice. 4. Install the exhaust manifold bolts and stud. Tighten the bolts/stud to 30 N.m (22 lb ft). Page 5135 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 6205 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16369 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 4485 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement Tools Required j 23523-F Crankshaft Balancer Remover and Installer Removal Procedure 1. Remove the drive belt. 2. Remove the cooling fan. Notice: To prevent damage to the end of the crankshaft when using a crankshaft balancer removal tool install a bolt in the crankshaft. Use a shorter bolt with the same threads as the crankshaft balancer bolt. This bolt will allow a place for the tool to push against. The shorter bolt is to keep from going past the threads in the crankshaft and damaging the crankshaft threads. 3. Remove the crankshaft balancer bolt and washer. 4. Remove the crankshaft pulley bolts and pulley. 5. Using J 23523-F, remove the crankshaft balancer. Notice: Refer to Fastener Notice. Page 3869 Junction Block - Right I/P, Top View Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 20520 Body Control Module (BCM) X5 Page 13593 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 16029 Page 9393 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 5848 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 13751 Vehicle Zoning Strategy Truck Zoning Page 2292 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 1560 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Page 24551 Notice to Customer General Motors released this product recall in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act because a defect that relates to motor vehicle safety exists in your vehicle. It was implemented to address the potential consequences of a printed circuit board electrical short within the Heated Washer Fluid System (HWFS). The significance of this failure can vary from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. This failure can occur at any time, even when the vehicle is unattended - parked and key not in the "ON" position. Note that a resulting under hood fire could also involve other nearby vehicles or structures. Performance of this recall procedure will allow your GM dealer to eliminate these risks by permanently removing the HWFS from your vehicle. In addition to the risk of a thermal incident, including a fire, it is possible that the HWFS will become inoperative at a future time. If this occurs, it will not be repaired or replaced by GM. Note that GM does not endorse or otherwise approve the Diagrams Rain Sensor: Diagrams Wiper/Washer Connector End Views Outside Moisture Sensor (CE1) Page 8067 Page 11578 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 12292 Torque Converter Clutch Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams 6L50/6L80/6L90 - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Page 3045 Page 11386 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 15226 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Notice: Refer to Fastener Notice. 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 N.m (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Rear Brake Caliper Overhaul (JH6, JH7) Rear Brake Caliper Overhaul (JH6, JH7) Page 12175 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. Tighten the bolt to 12 N.m (108 lb in). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Page 410 Page 9218 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 1896 Page 2222 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 8926 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Diagrams Oil Pressure Sender: Diagrams Displays and Gages Connector End Views Engine Oil Pressure (EOP) Sensor (Gas) Page 2931 Camshaft Position Sensor: Connector Views Engine Controls Connector End Views Camshaft Position (CMP) Sensor Page 23876 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5328 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 10106 Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine/Chassis (Regular Cab) Evaporative Emission Hoses/Pipes Replacement - Engine/Chassis (Regular Cab) Removal Procedure Important: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. 3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. Page 28 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 20985 Inspect the water deflector for a missing loft. Refer to the illustration above for an example of a correct loft (1) and a missing loft (2). If the loft is missing, replace the water deflector with a new service part. Inspect the opposite side door and replace the opposite side water deflector if necessary. Refer to Rear Side Door Water Deflector Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2957 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 22342 Rear Seat Cushion Frame Replacement (Extended Cab with AM7) Rear Seat Cushion Frame Replacement (Extended Cab with AM7) Page 8503 and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 6. Connect a test lamp between the relay coil B+ and the relay coil control circuit. 7. Ignition ON, command the powertrain relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the relay coil control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the relay coil control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 8. Connect a 20A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 9. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 10. If all circuits test normal, test or replace the relay. Component Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Test for 65-110 ohms of resistance between terminals 85 and 86 of the relay. ‹› If the resistance is not within the specified range, replace the relay. 3. Test for infinite resistance between following terminals: * Terminal 30 and 86 * Terminal 30 and 87 * Terminal 30 and 85 * Terminal 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 20A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm of resistance between terminals 30 and 87. ‹› If greater than the specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Relay Replacement (Within an Electrical Center) Relay Replacement (Attached to Wire Harness) * Underhood Electrical Center or Junction Block Replacement * Refer to Programming and Relearning for setup and programming. See: Testing and Inspection/Programming and Relearning Page 17487 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Page 215 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 2553 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Inflatable Restraint Front End Sensor Replacement (1500) Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement (1500) Inflatable Restraint Front End Sensor Replacement (1500) Page 11063 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 6147 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 6081 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors OnStar(R) - False Crash Detection Customer Calling Emergency Contact Module: All Technical Service Bulletins OnStar(R) - False Crash Detection Customer Calling TECHNICAL Bulletin No.: 08-08-46-002 Date: June 26, 2008 Subject: OnStar(R) Calls Unwanted, False Crash Detection Customer Calling (Reprogram SDM) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with OnStar(R) (RPO UE1) Condition Some customers may comment on receiving unwanted calls from the OnStar(R) Center. Cause During certain extreme vehicle maneuvers, the vehicle SDM may mistakenly detect a crash event and generate a call to the OnStar(R) call Center. The OnStar(R) advisor is connected to the vehicle to see if everyone is alright and if a request for emergency help is needed. Correction A revised SDM Operating System software has been developed to address this issue. Reprogram the Sensing and Diagnostic Module (SDM) with the controller option described as "SDM Sensing and Diagnostic Module" under Operating System using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 7210 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 12965 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 24229 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2542 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 11103 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 16535 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 20824 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Lighting - Turn Signals Have Increased Flash Rate Body Control Module: All Technical Service Bulletins Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11896 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 23391 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 13667 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 439 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 5152 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 3904 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Page 4575 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Install a 3/8 inch drive breaker bar to the drive belt tensioner arm. 2. Rotate the drive belt tensioner (2) counterclockwise in order to relieve tension on the belt. 3. If equipped without air conditioning (A/C), remove the belt (1) from the pulleys and the drive belt tensioner. 4. If equipped with A/C, remove the belt (1) from the pulleys and the drive belt tensioner. 5. Slowly release the tension on the drive belt tensioner (2). 6. Remove the breaker bar from the drive belt tensioner. 7. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the belt (1) around all the pulleys except the flat idler pulley. 2. Install a 3/8 inch drive breaker bar to the drive belt tensioner arm. 3. Rotate the belt tensioner (2) counterclockwise in order to relieve the tension on the tensioner. 4. If equipped with A/C, install the belt under the flat idler pulley. Service and Repair Band Apply Servo: Service and Repair 2-4 Servo Tools Required J 29714-A Servo Cover Depressor Removal Procedure 1. Remove the catalytic converter pipe. 2. Remove the heat shield bolts. 3. Remove the heat shield. 4. Support the transmission. 5. Remove the transmission crossmember. 6. Lower the transmission with a suitable jack. 7. Remove the oil pan bolt below the servo. 8. Install the J 29714-A. 9. Tighten the bolt on J 29714-A in order to compress the servo cover. 10. Remove the servo cover ring. 11. Remove the J 29714-A. Page 21596 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 476 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9761 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 12193 Page 11582 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Service and Repair Cabin Ventilation Duct: Service and Repair Air Inlet Assembly Replacement Page 6878 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 278 Door Lock, Window and Lighting System References Page 16026 Page 2982 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 21716 Memory Seat Module X3 (AN3) Lighting - Brake Lamps Turn Off After Stop/Pedal Applied Brake Light Switch: Customer Interest Lighting - Brake Lamps Turn Off After Stop/Pedal Applied TECHNICAL Bulletin No.: 08-08-42-003A Date: August 14, 2009 Subject: Stop Lamps Intermittently Turn Off After Coming to a Complete Stop While Still Having Pressure on Brake Pedal (Replace Stop Lamp Switch) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to provide a new part number. Please discard Corporate Bulletin Number 08-08-42-003 (Section 08 - Body & Accessories). Condition Some customers may comment on the stop lamps turning off prior to the brake pedal reaching the fully released position. Some customers may also comment on the stop lamps turning off while having light pressure on the brake pedal. Some customers with Integrated Trailer Brake Control (ITBC) may comment that the electronic trailer brakes disengage after the vehicle has come to a complete stop. This disengaging of the trailer brakes coincides with the stop lamps turning off. Cause This condition may be caused by not enough pressure being applied to the stop lamp switch to keep the brake lights on. Correction Technicians are to replace the stop lamp switch. The new stop lamp switch has a reduced internal spring apply force, which will allow the lamps to stay on with less applied brake force. 1. Refer to SI for Stop Lamp Switch replacement procedures. 2. Use the new Stop Lamp Switch, P/N 25981009. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12563 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 20667 Driver/Vehicle Information Display: Diagrams Object Detection Connector End Views Object Detection Connector End Views Information Center Telltale Assembly Page 1108 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11401 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Locations Hood Sensor/Switch (For Alarm): Locations Immobilizer Component Views Near the Hood Latch 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor - ISRVM Page 23176 minutes. After the system restarts, press the "EJECT" soft key to eject and remove the software update disc. Dealers should retain the software update disc for their use. Load the map DVD into the same slot located behind the display screen, DO NOT put in the top slot. Press the "CLOSE" soft key. Press the "OK" soft key. Press the "MENU" hard key. The clock will not be displayed until it is confirmed by completing step 16. Turn the engine OFF, open and close the drivers door. Wait for 10 minutes. Due to the load time of the system, there may be a short delay before the "Map Screen" appears. Restart the engine. After the map screen is displayed, verify that the clock is visible and touch the map screen to confirm that it can be scrolled. If the clock does not appear, repeat programming. The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. Verify that the destination search area is properly displayed. Press the "DESTINATION" hard key. Press "CHANGE SEARCH AREA" soft key. Select the correct area for the vehicle's location. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6733 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 5960 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. HVAC - Automatic Solar Sensor: Locations HVAC - Automatic HVAC Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 15850 Page 11775 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 7195 Page 22795 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5394 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 23638 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 3384 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement. Page 12901 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 17206 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 4939 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 11501 Ignition Control Module: Diagrams Engine Controls Connector End Views Ignition Control Module (ICM) Page 10947 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 8188 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 4994 Page 16155 Page 12564 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Auxiliary Battery Positive Cable Replacement Positive: Service and Repair Auxiliary Battery Positive Cable Replacement Auxiliary Battery Positive Cable Replacement (6.2L) Removal Procedure 1. Disconnect the auxiliary battery negative cable. 3. Lift the junction block retainers from the locked position (3) and rotate the retainers to the open position (1). 4. Remove the junction block. Page 22180 Page 8153 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 14782 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 9263 Page 16994 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 8326 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 22153 Seat Recline Position Sensor - Driver (AN3) Page 11427 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 24557 Page 14209 Seals and Gaskets: Service and Repair Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Removal Procedure 1. Remove the flange bolts. 2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 3. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal. 4. Remove the axle shaft from the tube. 5. Remove the gasket. 6. Clean the axle shaft flange and the outside face of the hub assembly. Installation Procedure 1. Install the gasket onto the axle shaft. 2. Install the gasket and the axle shaft into the axle tube. 1. Ensure the shaft splines mesh into the differential side gear. 2. Align the holes in the axle flange and the gasket with the holes in the hub. Notice: Refer to Fastener Notice. 3. Install the axle flange bolts. * For the 10.5 inch axle, tighten the rear axle flange bolts to 156 N.m (115 lb ft). * For the 11.5 inch axle, tighten the rear axle flange bolts to 185 N.m (136 lb ft). 4. Inspect and add axle lubricant to the axle housing, if necessary. Page 14775 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 23640 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 18790 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Page 8490 Knock Sensor: Description and Operation Knock Sensor (KS) System Description Purpose The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor (KS) system uses one or 2 flat response 2-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the control module through a low reference circuit. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Page 8327 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 16137 Page 727 Page 9852 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21814 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 13192 Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the bottom pan for excessive metal particles or other debris. A small amount of "friction" material in the bottom pan is a "normal" condition. If large pieces and/or metal particles are noted in the fluid or bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission. Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Remove the knock sensor heat shield bolt and shield. Page 6190 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 1038 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 21923 Memory Seat Module X6 (AN3) Page 13618 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 21393 Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Page 11021 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 5775 Page 16089 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Hood Open Assist Spring Replacement Hood Shock / Support: Service and Repair Hood Open Assist Spring Replacement Hood Open Assist Spring Replacement Page 23929 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 18650 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 6194 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 6412 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 24270 1 - Door Frame 2 - Window Switch - Left Rear (A31) 3 - Window Motor - Left Rear (A31) 4 Speaker - Left Rear Door 5 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 6 Door Latch Assembly - Left Rear Right Rear Door (Crew Cab) Page 23403 Parking Brake Warning Switch: Diagrams Park Brake Switch Park Brake Switch Page 14709 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 2634 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 2849 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 20409 Disclaimer Page 22196 Seat Back: Service and Repair Front Center Seat Back Cushion Pivot Cover Replacement (AE7) Front Center Seat Back Cushion Pivot Cover Replacement (AE7) Page 7372 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Locations Windshield Washer Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 6132 Air Flow Meter/Sensor: Connector Views Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 2166 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 2971 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 13434 17. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 18. Remove the 7 valve body checkballs. Important: Some models do not have an outer spring. Note spring usage during removal. 19. Remove the accumulator cover bolts (58, 59). 20. Remove the 1-2 accumulator cover and pin assembly (57). Page 8983 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 17103 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 16247 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 4616 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the drain plug and drain the engine oil in a suitable container. 3. Remove the oil filter. 4. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the oil filter gasket with clean engine oil. Notice: Refer to Fastener Notice. 2. Install the oil filter. Tighten the filter to 30 N.m (22 lb ft). Page 4151 Fuse Block - Underhood X2 (Pin N1 To P5) Fuse Block - Underhood X3 Page 8062 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 11328 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 20370 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 1206 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular/Extended Cab -10 Series) Page 12739 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 12872 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 16565 Disclaimer Page 6782 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 22586 1 - Door Frame 2 - Door Lock Switch - Driver 3 - Speaker - Left Front 4 - Door Latch Assembly Driver Passenger Door (AU3 -AN3/DL3) Page 22485 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 10378 Page 12865 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 13003 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 12889 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 11113 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 17371 X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Page 17908 Page 6787 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 13487 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 9547 5. Remove the knock sensor bolt and sensor. Installation Procedure Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). Page 2344 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 12342 17. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 18. Remove the 7 valve body checkballs. Important: Some models do not have an outer spring. Note spring usage during removal. 19. Remove the accumulator cover bolts (58, 59). 20. Remove the 1-2 accumulator cover and pin assembly (57). Page 13498 Transmission Speed Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Input and Output Speed Sensor Replacement Page 8469 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Allison - Automatic Transmission Transmission Mode Switch: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 17625 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Page 13762 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Accessories - Universal Home Remote Diagnostics Garage Door Opener Control Head: Technical Service Bulletins Accessories - Universal Home Remote Diagnostics Bulletin No.: 07-08-97-001 Date: September 28, 2007 INFORMATION Subject: Diagnostic Information For a Universal Home Remote (UHR) System That Is Not Operating and J 41450 HomeLink Tester Is Not Communicating With UHR Module Models: 2008 Buick Lucerne 2007-2008 Cadillac CTS, Escalade Models, SRX, STS, XLR 2008 Cadillac DTS 2007-2008 Chevrolet Avalanche, Corvette, Impala, Malibu, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon Models 2008 HUMMER H2, H2 SUT 2007-2008 Saturn AURA with Universal Home Remote System (RPO UG1) The purpose of this bulletin is to provide dealership personnel with diagnostic information and procedures for the new Universal Home Remote (UHR) system that is now available on certain 2007 and all 2008 model year vehicles listed above. When diagnosing a UHR system that is not operating, technicians may also find that the J 41540 HomeLink Tester is not communicating with the UHR module. The new UHR module does not have the software capability to communicate with the J 41540 HomeLink Tester. Technicians should first refer to PIT4073A for overall programming information. Next, contact Lear Car2U Hot Line for assistance prior to any repair. Please have the customer's original comments and your preliminary findings before making the call. Production Dates For Vehicles With Updated UHR Diagnostic Software Corvette, XLR, SRX and Model Year 2007 CTS Vehicles built after November 2006 Tahoe, Yukon/XL/Denali/XLDenali, Escalade/EXT/ESC, Avalanche, Suburban Vehicles built after March 2007 Sierra, Silverado Vehicles built after March 2007 Malibu, AURA, Impala, STS Vehicles built after April 2007 Lucerne, DTS, H2 software change incorporated for Model Year 2008 Disclaimer Page 8390 Knock Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 4385 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 13351 Transmission Control Module (TCM) 80-Way Connector (Part 2) Page 5082 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 6458 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 10857 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 10438 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 18619 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Page 13266 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Connect the internal wiring harness electrical connectors to the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) 23. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 24. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 20469 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 21402 Roof Rear Console Replacement (with DVD) Roof Rear Console Replacement (with DVD) Page 910 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 22703 The outline portion (1) of the insulator should Only be removed if the vehicle is equipped with the manual 4x4 shifter. All other vehicles should use the complete piece. Remove the two protective paper strips (1) from the insulator. Attach the glue side of the insulator to the top of the floor tunnel as shown in the above illustration. Reposition the carpet or rubber floor covering back down into position. Install the body lock pillar trim panels. Refer to Body Lock Pillar Trim Replacement in SI. Install the jack and the jack handle kit. Refer to Jack Stowage Cover Replacement in SI. Install the IP support bracket, bolts and trim covers. Tighten Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 6105 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 10899 Page 3010 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 9534 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 12936 Page 8435 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 11690 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 4402 Wheel Fastener: Specifications Wheel Nuts Tighten the nuts evenly and alternately in order to avoid excessive runout. Tighten the wheel nuts as shown to .................................................................................................................................................... 190 N.m (140 lb ft). Page 8403 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2538 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Endgate Latch Replacement Tailgate Latch: Service and Repair Endgate Latch Replacement Endgate Latch Replacement Page 155 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 952 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 15222 Brake Caliper: Overhaul Front Brake Caliper Overhaul (JH6, JH7) Front Brake Caliper Overhaul (JH6, JH7) Caution: Refer to Brake Dust Caution. Caution: Refer to Brake Fluid Irritant Caution. Disassembly Procedure 1. Remove the brake caliper. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Important: The brake calipers use phenolic pistons that have stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Page 16922 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 21554 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 9527 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 5272 Page 19656 For vehicles repaired under warranty use, the table. Disclaimer Page 14719 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring A/C - HVAC Control Module Lockup During Reprogramming Control Module HVAC: All Technical Service Bulletins A/C - HVAC Control Module Lockup During Reprogramming Bulletin No.: 06-01-39-014 Date: December 06, 2006 INFORMATION Subject: Information On HVAC Control Module Lockup During Reprogramming Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) The purpose of this bulletin is to alert technicians to a condition they may encounter while trying to reprogram a Heating, Ventilation and Air Conditioning (HVAC) control module. If the HVAC control module reprogramming event is interrupted, the control module may go into a "lock up" mode. This will cause the HVAC control module to disable communications and a second try at reprogramming will fail. The interruption may be caused by a software anomaly inside the HVAC control module. If the HVAC reprogramming event was interrupted and a subsequent reprogramming attempt fails, perform a battery reset. This can be accomplished by either removing and reinstalling the HVAC BATT fuse, located in the underhood fuse block, or by disconnecting and reconnecting the HVAC control module connector C2. Connector C2 is grey in color with 16 cavities. Once the battery reset has been performed, the HVAC control module will resume communications and will then be able to be reprogrammed. The Warranty Parts Center (WPC) has received HVAC control modules that have been returned and described as non-functional but were tested with no problems found. If the module has been replaced due to a failed second attempt at reprogramming caused by the lock up, the module will be returned and charged back to the dealer. Technicians must also remember that after a new HVAC control module has been installed into a vehicle, it must be programmed, otherwise it will not be functional. Disclaimer Page 15509 Page 22590 Driver Door Switch (DDS) X3 (AN3/DL3) Page 1989 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 17785 3. Install the steering column seal. 4. Install the steering shaft coupling nut (1) and bolt (2) at the steering shaft coupling. Tighten the nut and bolt to 50 N.m (37 lb ft). 5. Remove anti-rotation pin J 42640 from the steering column lower access hole. Page 6080 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 4349 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 8414 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 940 Page 14184 7. Place an alignment mark between the pinion and the pinion yoke. 8. Remove the pinion gear bearing retainer bolts. 9. Remove the pinion gear bearing retainer and the pinion. 10. Remove the selective shim. 11. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. 12. Install the J 8614-01 as shown. 13. Remove the pinion nut while holding the J 8614-01. 14. Remove the washer. 15. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 (3) as shown. 16. Remove the pinion yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 (3). 17. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. 18. Remove the outer pinion bearing. Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Retractor: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 16144 1 - Battery - Right 2 - Fuse Holder - Underhood 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 Fuse Block - Underhood 8 - X109 9 - Battery - Left (6A6/TP2) 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Fuse Block Jumper Harness (9L4) Page 15272 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Measurement Brake Rotor Assembled Lateral Runout Measurement Tools Required * J 39544-KIT Torque-Limiting Socket Set, or equivalent * J 41013 Rotor Resurfacing Kit * J 42450-A Wheel Hub Resurfacing Kit * J 45101 Hub and Wheel Runout Gage * J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution. Important: * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. See: Brake Rotor Thickness Measurement 1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already. Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these conditions, perform the following steps: 1. Remove the brake rotor from the vehicle. 2. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 3. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface of the brake rotor. 4. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Install the rotor to the hub/axle flange using the matchmark made prior to removal. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1), and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Page 11169 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 22532 For vehicles repaired under warranty, use the table. Disclaimer Page 20659 * Park Tilt Mirrors * Smart High Beams Average Fuel Economy Average fuel economy is calculated using the equation: AFE = Distance/Fuel * Distance = The accumulated distance travelled since the last reset of this value * Fuel = The accumulated fuel consumption since the last reset of this value The engine control module (ECM) sends the average fuel economy GMLAN message to the instrument panel cluster (IPC). The value of this mode is retained during ignition OFF and can be changed between English units and metric units by selecting from the driver information center (DIC) options menu. Average Speed Average speed is calculated using the equation: Average Speed = AVS Distance/AVS Time * Distance = The accumulated distance travelled since the last reset of this value * Ignition On = The accumulated ignition on time since the last reset of this value Oil Life Remaining The ECM sends the oil life remaining percentage to the IPC via GMLAN message. The instrument panel cluster receives a GMLAN message indicating the engine oil life remaining. The DIC displays the current percentage of the GM Oil Life System as determined by the ECM. When the oil life remaining percentage drops below 5 percent, the DIC displays CHANGE ENGINE OIL SOON. When the engine oil is changed, reset the GM Oil Life System. Refer to GM Oil Life System Resetting. Fuel Range This message indicates the estimated distance that the vehicle can travel under the current fuel economy and fuel level conditions since the last battery connection to the IPC. Fuel Range is calculated using the equation: Fuel Range = Range Distance/Range Fuel Used. * Range Distance = The accumulated distance travelled since the last reset of this value. * Fuel Used = The accumulated fuel delivered since the last reset of this value The ECM sends the fuel range value to the IPC. The IPC receives a GMLAN message with fuel information. The fuel range value is retained during ignition OFF and can be changed between English and Metric units by accessing the DIC English/Metric menu. The Fuel Range display cannot be reset. LOW is displayed when fuel range is below a predetermined value. Fuel Used The DIC calculates and displays the total amount of fuel used since the last reset operation. You can reset the fuel used mode by depressing and holding the Set/Reset button for more than 3 seconds. The value of this mode is retained during ignition OFF. Instantaneous Fuel Economy (IFE) Instantaneous fuel economy (IFE) is calculated using the equation: IFE = Distance/Fuel Used. * Distance = The accumulated distance travelled for the last 2 seconds * Fuel = The accumulated fuel delivered for the last 2 seconds The IPC receives a GMLAN message from the ECM. The distance information is calculated by the IPC using the vehicle speed information from the ECM. These values are retained during ignition OFF and can be changed between English and Metric units accessing the DIC English/Metric menu. The IFE display cannot be reset. Tire Pressure Monitor The IPC receives a GMLAN message from the tire pressure monitoring (TPM) system for front and rear tire pressure data. The DIC will display the pressure for each of the front and rear tires. When a tire with low air pressure is present, the DIC displays XXXX XXXX TIRE PRESSURE LOW. Trip Time The timer records elapsed time starting from activation. When the DIC displays the timer, pressing the Set/Reset switch for 1 second on the DIC resets the timer. Pressing the Set/Reset button on the DIC switch for approximately 1 second starts and stops the timer. The DIC displays the timer in one of the following formats: Page 22591 Driver Door Switch (DDS) X4 (AN3) Page 23056 Page 446 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 5452 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 23185 For vehicles repaired under warranty, use the table. Disclaimer Page 7540 Page 10256 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3958 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 4139 Junction Block - Right I/P X3 Page 19917 Page 11372 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 15050 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 9540 Knock Sensor: Description and Operation Knock Sensor (KS) System Description Purpose The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor (KS) system uses one or 2 flat response 2-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the control module through a low reference circuit. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Page 3444 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Crew Cab) Rear Side Door Window Switch Replacement (Crew Cab) Page 2810 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 14059 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Upper Control Valve Body Assembly Disassembled Views (6L80) Upper Control Valve Body Assembly 313 - Control Valve Body Locator Pin 321 - Control Valve Upper Body 322 - Control Valve Body Locator Pin 323 - Retainer 324 - Actuator Feed Limit Valve Spring 325 - Actuator Feed Limit Valve 326 - Clutch Regulator Valve Spring 327 - CBR1/4-5-6 Clutch Regulator Valve 328 - Clutch Regulator Valve Bore Plug 329 - Clutch Boost Valve 330 - Clutch Boost Valve Spring 334 - 2-6 Clutch Regulator Valve 335 - 2-6 Clutch Regulator Valve Gain Valve 336 - 3-5 Reverse Clutch Regulator Valve 337 - 1-2-3-4 Clutch Regulator Valve 338 - Shuttle Valve Page 1133 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 15467 Tools Required j 37043 Park Brake Cable Release Tool Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the left park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the left park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Remove the park brake cable from the cable guides. 7. Remove the brake shoes. 8. Using the J 37043 (1), remove the park brake cable from the backing plate. Page 5472 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 23811 6. Remove 100 mm (3.9 in) of harness tape, starting from the back of the connector, to make the repair. 7. Locate and remove the 240 circuit (red wire with white stripe) (1) from cavity E2. 8. Cut off the terminal. 9. Locate circuit 3040 (red wire with a white stripe) (2) located in cavity D1 of connector X1 and cut the 240 and 3040 wires 75 mm (3 in) from the back of the connector. Strip the ends of the wires. Page 4417 The identification tag on the rear half of the transfer case provides the information shown. Disclaimer Page 15521 Vacuum Brake Booster: Locations Antilock Brake System Component Views Left Side of the Engine Compartment 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (- MYC) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Page 11592 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 15250 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Page 11475 For vehicles repaired under warranty, use the table. Disclaimer Page 7596 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 10629 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 995 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9622 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 23100 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 7374 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 19508 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 13769 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 10204 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 10489 Important: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. Command the fuel pump relay ON with a scan tool. 3. Observe the fuel pressure gage with the fuel pump commanded ON. The fuel pressure should be 345-414 kPa (50-60 psi). ‹› If the fuel pressure is not 345-414 kPa (50-60 psi), refer to Fuel System Diagnosis. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 4. Monitor the CH-48027 for one minute. The fuel pressure should not decrease more than 34 kPa (5 psi). ‹› If the fuel pressure decreases more than 34 kPa (5 psi), refer to Fuel System Diagnosis. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 5. Perform the Fuel Injector Balance Test with Special Tool or the Fuel Injector Balance Test with Tech 2. Fuel Injector Balance Test with Special Tool 1. Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0.5-2.5 amp position. 2. Connect the J 39021, J 39021-210, and the J 39021-301 to the fuel meter body. 3. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last command, as the fuel pressure begins to slowly degrade and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record this fuel pressure. This is the starting pressure at which you will pulse each injector. 4. Command the fuel pump relay ON one more time and energize the fuel injector by depressing the Push to Start Test button on the J 39021 at the previously selected pressure. 5. After the injector stops pulsing, select Min from the Display Mode and record the Min pressure. Important: New test results will not be recorded if the Min/Max results are not cleared after each injector is tested. 6. Clear the Min/Max results. 7. Select Normal from the Display Mode. 8. Repeat steps 2 and 4 through 7 for each fuel injector. 9. Perform the Pressure Drop Calculation. Fuel Injector Balance Test with Tech 2 1. Command the fuel pump relay ON and then OFF three times with a scan tool. On the last command, as the fuel pressure begins to slowly degrade and stabilize, select a fuel pressure within 34 kPa (5 psi) of the maximum pump pressure. Record this fuel pressure. This is the starting pressure at which you will pulse each injector. 2. With a scan tool, select the Fuel Injector Balance Test function within the Special Functions menu. 3. Select an injector to be tested. 4. Press Enter to prime the fuel system. 5. Energize the fuel injector by depressing the Pulse Injector button on the scan tool at the previously selected pressure. 6. After the injector stops pulsing, select Min from the Display Mode on the CH-48027 and record the Min pressure. Important: New test results will not be recorded if the Min/Max results are not cleared after each injector is tested. 7. Clear the Min/Max results on the CH-48027. 8. Select Normal from the Display Mode on the CH-48027. 9. Press Enter on the scan tool to bring you back to the Select Injector screen. 10. Repeat steps 3 through 9 for each fuel injector. 11. Perform the Pressure Drop Calculation. Pressure Drop Calculation 1. Subtract the minimum pressure from the starting pressure for one fuel injector. The result is the pressure drop value. 2. Obtain a pressure drop value for each fuel injector. 3. Add all of the individual pressure drop values except for the injector suspected of being faulty. This is the total pressure drop. 4. Divide the total pressure drop by the number of fuel injectors that were added together. This is the average pressure drop. The difference between any individual pressure drop and the average pressure drop should not be more than 20 kPa (3 psi). ‹› If the difference between any individual pressure drop and the average pressure drop is more than 20 kPa (3 psi), replace the fuel injector, E-85 only. All other engine, refer to Fuel Injector Cleaning. Repair Instructions Page 15926 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 12026 Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 2 (PCS2) Pressure Switch Manifold (PSM) Page 3809 Refrigerant: Fluid Type Specifications Refrigerant System Capacities Page 16490 X414 Chassis Harness to Camper Harness (UY2/8S3) X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Page 9477 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Inspection Procedure Notice: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner. Important: When the engine is operating the drive belt tensioner arm will move. Do not replace the drive belt tensioner because of movement in the drive belt tensioner arm. 1. Remove the drive belt. 2. Move the drive belt tensioner through it's full travel. * The movement should feel smooth * There should be no binding * The tensioner should return freely 3. If any binding is observed, replace the drive belt tensioner. Refer to Drive Belt Tensioner Replacement. 4. Install the drive belt. Page 12129 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 11924 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 16149 Fuse Block: Locations HVAC - Automatic HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 22913 Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 10834 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 15262 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Page 11671 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 5014 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 5199 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 16433 X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) X321 Page 546 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 11333 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 10549 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 16948 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 11557 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 5314 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 6398 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 823 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Diagrams Fuel Gauge Sender: Diagrams Displays and Gages Connector End Views Fuel Pump and Sender Assembly - Front (Gas) Fuel Pump and Sender Assembly - Rear (Gas +LY6) Page 23925 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 16850 Disclaimer Locations Crankshaft Position Sensor: Locations Engine Controls Component Views Right Side of Engine 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 5540 Disclaimer Page 17042 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 2349 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 9755 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 15809 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. A/C - Compressor/Serpentine Belt Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins A/C Compressor/Serpentine Belt Noise TECHNICAL Bulletin No.: 07-01-38-010A Date: October 06, 2009 Subject: Air Conditioning (A/C) Compressor and/or Serpentine Belt Noise at Vehicle Start-up (Reprogram Powertrain Control Module (PCM)) Models: 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon Models Equipped With Air Conditioning (RPOs CJ2 or CJ3) Supercede: This bulletin is being revised to update the Condition and Correction information. Please discard Corporate Bulletin Number 07-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on air conditioning (A/C) compressor slugging and/or serpentine belt or pulley rattle noise at vehicle start-up in warmer outside ambient temperature conditions. Others may describe the noise as a belt chirp or as a thumping/grinding noise coming from the A/C compressor at vehicle start-up. Cause This condition may be caused by the A/C compressor trying to move liquid refrigerant through the system. Correction - A revised PCM calibration has been released to address this condition. Reprogram the PCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. - When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. - When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. - During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information Note *Please use Failure Code 93 for any warranty claims submitted using this bulletin. For vehicles repaired under warranty, use the table above. Page 8359 High Speed Bus - 2 of 3 Page 13267 Fluid Pressure Sensor/Switch: Service and Repair Allison - Automatic Transmission Pressure Switch Manifold Replacement Removal Procedure Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Caution: Refer to Battery Disconnect Caution. 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Page 24215 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 9168 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Upper Intermediate Steering Shaft Replacement Steering Shaft: Service and Repair Upper Intermediate Steering Shaft Replacement Upper Intermediate Steering Shaft Replacement Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. 1. Install anti-rotation pin J 42640 in the steering column lower access hole. 2. Mark the relationships of the following components: 1. Mark the relationship of the upper intermediate steering shaft to the steering column. 2. Mark the relationship of the upper intermediate steering shaft to the steering shaft coupling 3. Remove the steering shaft coupling nut (1) and bolt (2) at the upper intermediate steering shaft. 4. Remove the steering column seal. Page 594 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 11908 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 22513 Seat Heater: Symptom Related Diagnostic Procedures Symptoms - Seat Heating and Cooling Symptoms - Seat Heating and Cooling Important: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle before using the Symptom Tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data link. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Heated Seats Description and Operation. Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the system. * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections. See: Testing and Inspection/Component Tests and General Diagnostics Symptom List Refer to Heated Seat Inoperative in order to diagnose the symptom. See: Heated Seat Inoperative Heated Seat Inoperative Heated Seat Inoperative Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. * Review Strategy Based Diagnosis for an overview of the diagnostic approach * Diagnostic Procedure Instructions provides an overview of each diagnostic category Circuit/System Description The heated seat system operation is controlled through the switch inputs to the driver and passenger door modules. When a heated seat switch is pressed a GMLAN message is sent to the Memory Seat Module (MSM) indicating the switch is active. The MSM monitors the heated seat switch inputs and determines the appropriate operating mode. When a heated seat function is activated the MSM will send a GMLAN message to the door module to illuminate the appropriate indicators. The memory seat module controls the voltage supply and the ground circuits to the seat heater elements. When a heated seat function is commanded active, the seat module will switch battery voltage to the heater element supply circuits, and ground is provided through pulse width modulation (PWM) low side drive control circuits. During heated seat operation both the seat back and cushion heater elements are supplied battery voltage. The seat module grounds the appropriate control circuits for back only or back and cushion heating modes, and opens or closes the active control circuits as necessary in order to maintain the desired seat temperature. The seat module relies on 4 independent inputs from thermistors located in the seat back and seat cushion of the driver and passenger seats to control heated seat temperatures. The thermistors are 2-wire sensors supplied with a 5-volt referenced signal circuit and a low reference circuit from the seat module. Resistance through the thermistors varies with temperature causing the heated seat sensor signal circuit voltage levels to decrease as the seat temperatures rise. Circuit/System Testing 1. Ignition ON, verify that the driver and passenger door switch heated seat switch parameters display Active while the heated seat switches are pressed. ‹› If either of the switch parameters are continuously Active or Inactive while the switch is pressed, perform the heated seat switch component test. 2. Verify that the MSM driver and passenger seat HVC mode and level parameters are displayed correctly as the heated seat switches are activated through all of the operating modes. Page 2289 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Locations Seat Heater Switch: Locations Power Seat Component Views Memory/Heated Seat Switch 1 - Outside Rearview Mirror (OSRVM) - Driver 2 - Memory/Heated Seat Switch (AN3) Page 4232 Tire Pressure Module: Service and Repair Control Module Setup Remote Control Door Lock Receiver (RCDLR) Setup After remote control door lock receiver assembly replacement, the following procedures must be performed in the order that they appear for the tire pressure monitor (TPM) System to function properly. The RCDLR also requires keyless entry transmitter programming after replacement. Refer to Transmitter Programming. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool select Vehicle Control System. 4. Select Module Setups. 5. Select Remote Control Door Lock Receiver. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle drivers door placard sticker. 9. Select the rear tire pressure as noted on the vehicle drivers door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After RCDLR assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the RCDLR memory. Refer to Tire Pressure Sensor Learn. Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Page 2246 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. A/T Controls - DTC P1825/P182E or P1915/MIL ON PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 14894 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 3630 Disclaimer Page 5867 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 2582 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Notice: Refer to Fastener Notice. 4. Install the VSS bolt (2). Tighten the bolt to 11 N.m (97 lb in). Page 9441 Page 14767 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13473 Transmission Position Switch/Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 23123 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 22698 Important Ensure that the foam is securely wedged between the outboard edges of the insulator and the wiring harnesses/sheet metal, making sure that any C-pillar wiring harnesses/connectors are routed forward of the insulator and foam, and not trapped behind either of them. 5. Install a length of *Duck Brand Window Air Conditioner Insulating Strip Seal P/N 1284075, or equivalent, down each side C-pillar. 6. Complete the installation of the insulator panel and interior trim. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Duck Brand products, or equivalent, can be obtained from your local hardware or home improvement store. *GM‹›P/N‹›12378195 is not available in Canada. However several equivalents such as Evercoat (Q-Pads) P/N 100116 and Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 can be obtained by contacting Dominion Sure Seal at 1-800-265-0790. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8266 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 8537 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 24666 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 17672 5. Remove the idler arm bolts (3) and the nuts (1) at the vehicle frame. 6. Remove the idler arm (2) from the vehicle. Installation Procedure 1. Position the idler arm (2) to the vehicle frame. Notice: Refer to Fastener Notice. 2. Install the idler arm bolts (3) and nuts (1) to the frame. Tighten the bolts and nuts to 105 N.m (78 lb ft). 3. Install the idler arm (1) to the relay rod (2). Page 10471 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 5392 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 18514 Refrigerant Oil: Fluid Type Specifications PAG Oil GM P/N 12378526 for United States PAG Oil GM P/N 88900060 for Canada Description and Operation Positive Crankcase Ventilation: Description and Operation Crankcase Ventilation System Description General Description A crankcase ventilation system is used to consume crankcase vapors in the combustion process instead of venting them to the atmosphere. Fresh air from the intake system is supplied to the crankcase, mixed with blow by gases and then passed through a calibrated orifice into the intake manifold. Operation The primary control is through the positive crankcase ventilation (PCV) orifice which meters the flow at a rate depending on inlet vacuum. The PCV orifice is an integral part of the valve cover. If abnormal operating conditions occur, the system is designed to allow excessive amounts of blow by gases to back flow through the crankcase vent into the intake system to be consumed by normal combustion. Results of Incorrect Operation A plugged orifice may cause the following conditions: * Rough idle * Stalling or slow idle speed * Oil leaks * Sludge in engine A leaking orifice may cause the following conditions: * Rough idle * Stalling * High idle speed Page 4503 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Page 9795 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 16108 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11733 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 17373 X303 Body Harness to Driver Seat Harness (-AN3) Page 17069 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 20558 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Outer Bracket Replacement (Chevrolet) Front Bumper Impact Bar Outer Bracket Replacement (Chevrolet) Page 7160 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Exhaust System - Underbody Rattle/Clunk/Rumble Noise Seals and Gaskets: All Technical Service Bulletins Exhaust System - Underbody Rattle/Clunk/Rumble Noise Bulletin No.: 07-06-05-003 Date: March 08, 2007 TECHNICAL Subject: Exhaust Pipe / Muffler Rumble, Rattle, Moan, Drone, Vibration Noise (Align Exhaust and Install New Exhaust Seals) Models: 2007 Chevrolet Silverado 1500 Series Only 2007 GMC Sierra 1500 Series Only Condition Some customers may comment on an underbody rattle/clunk/rumble noise. Cause This condition may be due to insufficient clearance between the exhaust and transmission crossmember. Correction Measure the clearance between the exhaust pipe and the transmission crossmember. If the clearance is between 15 mm-30 mm (0.59 in-1.18 in), this is not the cause of the customer's concern. Do not proceed with this bulletin. Continue to diagnose the customer's concern. If the clearance is less than 15 mm (0.59 in), realign the exhaust following steps 2-6. Disconnect the Y-pipe outlet from the exhaust muffler assembly. Loosen both the left and right exhaust manifold pipe nuts. It may be necessary to remove the right side 02 sensor to gain access to all the right side exhaust manifold nuts. The left exhaust MUST be torqued first. Tighten the left exhaust manifold pipe bolts in the sequence indicated in illustration "A" above. Tighten: Tighten the bolts to 50 N.m (37 lb ft). Monitor the clearance between the exhaust pipe and the transmission crossmember. It may be necessary to push up on the exhaust while tightening the right exhaust manifold nuts in order to achieve a minimum clearance of 15 mm (0.59 in). Page 6316 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 22402 Page 17850 Page 20323 Dinghy towing is permitted on the trucks shown with the transfer case placed in the Neutral position. Refer to the end of this bulletin for identification information to determine type of transfer case. The vehicles shown should NOT be dinghy towed because the transfer cases in these vehicles either have no neutral position or do not have an internal oil pump to provide lubrication while being towed. In order to properly tow the vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when towing with all four tires on the ground is unavoidable, both the front and the rear propeller shafts must be removed in order to prevent damage to the transfer case and/or transmission. Because front and rear propeller shafts are matched to attaching components at assembly, refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Towing Procedure In order to properly dinghy tow the vehicle, use the following procedure: 1. Firmly set the parking brake. Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Instruments - Hard to See/Poor Backlighting Instrument Panel Control Module: All Technical Service Bulletins Instruments - Hard to See/Poor Backlighting Bulletin No.: 07-08-49-029A Date: January 25, 2008 TECHNICAL Subject: Instrument Panel (IP) Gauges/Gages Difficult to Read or See Poor Backlighting (Replace IP and Program) Models: 2007 Chevrolet Avalanche Silverado Suburban Tahoe 2007 GMC Sierra Sierra Denali Yukon Yukon Denali Yukon XL Yukon Denali XL Supercede: This bulletin is being revised to reflect the latest Utility software part number. Please discard Corporate Bulletin Number 07-08-49-029 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) gauges are difficult to read due to poor backlighting. This condition does not affect the IP cluster operation. Correction DO NOT program the service software into existing 2007 clusters. The service software is designed to work only with the 2008 cluster hardware, which includes a new microprocessor. For IP clusters replaced/programmed due to a customer concern of poor backlighting, warranty claims must be submitted using the labor operation listed in this bulletin. Refer to the Warranty Section for more information. Program the replacement IPC using TIS2WEB Pass-Thru Programming. Select "I/PC" from the Supported Controllers table in TIS2WEB to complete the programming. DO NOT select I/PC Set-up. Mileage and/or Engine Hours must be set by the ESC's prior to installing the IP in the vehicle. DENALI CUSTOMER'S ONLY - Please advise the customer that 2008 Denali clusters are not available. In order to correct this condition, a 2008 Yukon or Sierra cluster will have to be installed in the vehicle. The customer must advise the dealer whether they wish to keep the current 2007 Denali cluster or replace it with a 2008 Yukon or Sierra cluster (which will correct the condition). Programming a 2007 cluster with the 2008 service software can drain the battery and potentially cause a "no start" condition. If the customer is dissatisfied with the IP cluster visibility the current (2007) cluster should be replaced with the 2008 hardware/software. Refer to the charts listed in the Parts Information section of this bulletin to determine the new IP cluster and software part numbers. Page 3021 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 1831 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2498 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 24507 dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Windshield Washer Solvent Heater Removal WINDSHIELD WASHER SOLVENT HEATER REMOVAL 1. Disconnect the windshield wiper solvent inlet and outlet hoses (1) from the windshield washer solvent heater assembly and from the two plastic inlet and outlet windshield wiper solvent hoses. Note Do NOT remove the connector retention clips from the connectors. Do NOT remove the assembly bracket from the engine compartment. 2. Disconnect the two electrical connectors at the windshield washer solvent heater assembly. 3. Remove the windshield washer solvent heater assembly from the assembly bracket using a small flat blade screwdriver. 4. Place the windshield washer solvent heater assembly on a work bench. 5. Cut the two-wire connector from the windshield washer solvent heater assembly. Vary the length of the red and black wires on the connector. Refer to illustration. Page 11601 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 7530 Accelerator Pedal Position Sensor: Diagrams Engine Controls Connector End Views Accelerator Pedal Position (APP) Sensor Page 19286 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Page 2069 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 18309 6. Install the clutch plate assembly (2). Important: Ensure the drive plate does not drag against the pulley when the pulley is rotated. 7. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.35-0.65 mm (0.014-0.026 in) air gap. Notice: Refer to Fastener Notice. 8. Install the clutch plate retaining bolt (1). Tighten the bolt to 18 N.m (13 lb ft). 9. Install a ratchet into the belt tensioner adapter opening. 10. Rotate the belt tensioner counterclockwise in order to relieve the tension on the belt. 11. Install the belt to the A/C compressor. 12. Slowly release the tension on the belt tensioner. 13. Remove the ratchet from the belt tensioner. Page 8479 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 21984 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement (Crew Cab) Sunroof Motor/Actuator Replacement (Crew Cab) Page 13996 Warranty Information For repairs performed under warranty, use the applicable published labor code. Disclaimer Page 2541 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 9729 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 2116 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 23392 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 7561 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 20562 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Extension Replacement Front Bumper Impact Bar Extension Replacement Page 13020 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 932 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 9166 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 13785 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 16025 Page 11766 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 2282 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 10431 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9312 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 11357 Page 13784 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 1505 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Page 879 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 16678 1 - Rear Seat Audio (RSA) Controller (UK6) 2 - Auxiliary Power Outlet - Console (D07) 3 - Audio Amplifier (UQA) 4 - Auxiliary Power Outlet - Bin (D07) 5 - Noise Compensation Microphone (Y91) 6 - Audio/Video Adapter (U42) Page 21824 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 12631 Tighten the bolt to 11 N.m (97 lb in). 6. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 9. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 3980 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 22140 Seat Lumbar Horizontal Motor - Driver (AN3) Telescoping Actuator C1 Page 11057 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 2802 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 10541 Vehicle Zoning Strategy Truck Zoning Page 17038 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 21697 Passenger Door Switch (PDS) X4 (AN3) Page 11531 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 7041 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 1121 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11906 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 24389 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3717 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Page 2674 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 16745 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Drivetrain - Rear Drive Axle Whine Noise Universal Joint: Customer Interest Drivetrain - Rear Drive Axle Whine Noise Bulletin No.: 06-04-17-002A Date: January 12, 2007 TECHNICAL Subject: Rear Drive Axle Whine Noise (Replace Slip Yoke Assembly) Models: 2004-2007 Chevrolet Silverado (Classic) 1500 Series 2WD Crew Cab Models (C15543) 2004-2007 GMC Sierra (Classic) 1500 Series 2WD Crew Cab Models (C15543) Supercede: This bulletin is being revised to include additional model information. Please discard Corporate Bulletin Number 06-04-17-002 (Section 04 - Driveline/Axle). Condition Some customers may comment on a slight axle whine noise heard only at certain speeds, typically on coast conditions between 72-96 km/h (45-60 mph). Cause "Inherent" ring and pinion gear whine. All gear driven units, such as automotive rear axles, produce some level of noise that cannot be eliminated with conventional adjustments and repairs. "Inherent" axle noise can be described as a slight noise heard only at a certain speed (typically between 72-96 km/h (45-60 mph) on most General Motors(R) trucks). The presence of this noise is not indicative of a functional concern with the axle assembly. However, some customers may find that this inherent axle noise is unacceptable. Correction Using the service procedures in SI, replace the propshaft front slip yoke and u-joint with a tuned damper slip yoke with u-joint assembly, P/N 19151749, ONLY after diagnosis concludes that it is an "inherent" rear axle noise and no physical damage or incorrect adjustment exists. Do NOT replace the propshaft assembly. If the noise is not correctly diagnosed as "inherent" and having a peak in the narrow speed range of 72-96 km/h (45-60 mph), the addition of a tuned damper slip yoke and u-joint can aggravate the perceptible noise level. It is extremely important to first diagnose the rear axle noise as "inherent". Refer to the following diagnostic information and procedure for rear axle noise in SI: Diagnostic Starting Point - Rear Drive Axle Symptoms - Rear Drive Axle Rear Drive Axle Noises Noisy in Drive Parts Information Warranty Information Page 1276 Control Module: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Control Module (TCM), Engine Side Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Page 2075 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18773 1 - Outside Rearview Mirror - Passenger 2 - Door Lock Switch - Passenger (AU3 -AN3/DL3) 3 Passenger Door Switch (PDS) (AN3/DL3) 4 - Door Latch Assembly - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) 6 - Speaker - Right Front 7 - Window Motor - Passenger (A31) 8 - Window Switch - Passenger (A31 -AN3/DL3) 9 - Heated Seat Switch Passenger (AN3) Left Rear Door (Extended Cab) Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 4355 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 12290 Torque Converter Clutch Solenoid: Connector Views 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Page 14063 Lower Control Valve Body Assembly Disassembled Views (6L90) Lower Control Valve Body Assembly 323 - Retainer 328 - Clutch Regulator Valve Bore Plug 338 - Shuttle Valve 351 - Control Valve Lower Body 352 - Clutch Select Solenoid Valve 353 - Clutch Select Solenoid Valve Spring 354 Manual Valve 355 - TCC Regulator Apply Valve 356 - Clutch Piston Dam Feed Regulator Valve 357 - Clutch Piston Dam Feed Regulator Valve Spring Ball Check Valve Locations Ball Check Valve Locations Page 7380 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 17086 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10913 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 7411 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 16177 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 3195 1 - Window Switch - Right Rear (ABV) 2 - Window Motor - Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 4 - Speaker - Right Rear Door Left Rear Door (Crew Cab) Page 10184 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 5453 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 9616 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 24427 Page 7937 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 12002 6. Inspect for evidence of improper arcing. * Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. * Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. * Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). * Inspect for a broken or worn side electrode (3). * Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. * Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. * Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. * Inspect for excessive fouling. 7. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection 1. Normal operation-Brown to grayish tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: * Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion * Reduced ignition system voltage output - Weak ignition coils - Worn ignition wires - Incorrect spark plug gap * Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not affect spark intensity unless they form into a glazing over the electrode. 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor Assembly, Wiring Harness Side Page 12367 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 5182 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 7268 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 5715 Page 23558 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 11147 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 18671 Repairs and Inspections Required After a Collision: Service and Repair Supplemental Inflatable Restraints Repairs and Inspections Required After a Collision Accident With or Without Inflator Module Deployment - Component Inspections Caution: Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. After any collision, inspect the following components as indicated. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. * The steering column-Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection. See: Steering Column * The instrument panel (I/P) knee bolsters and mounting points-Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. * The I/P brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of damage. * The seat belts-Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks. See: Seat Belt Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Operational and Functional Checks * The I/P mounting points and brackets-Inspect for bending, twisting, buckling, or any other type of damage. * The roof rail and roof rail module mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * The seats and seat mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * Passenger seat bottom equipped with Passenger Presence System (PPS)-Check for any DTCs or problems that may cause the PPS not to function properly. Accident With Frontal Air Bag Deployment - Component Replacement and Inspections After a collision involving air bag deployment, replace the following components. If you detect any damage, replace the component. If you detect any damage to the mounting points or mounting hardware, repair or replace the mounting points and mounting hardware as needed. Important: The front passenger seat is equipped with a PPS, which detects an occupant. If the requirements for disabling the I/P air bag are met then the PPS will communicate with the SDM to disable/turn off the I/P air bag, even in a accident. For more information on the PPS Refer to SIR System Description and Operation. * Inflatable restraint front end sensors * Inflatable restraint I/P module, if deployed and after performing the necessary inspections listed above * Inflatable restraint sensing and diagnostic module (SDM) * Inflatable restraint steering wheel module * Inflatable restraint steering wheel module coil * Seat belt pretensioners Perform additional inspections on the following components: * Steering wheel module coil and the coil wiring pigtail-Inspect for melting, scorching, or other damage due to excessive heat. * Mounting points or mounting hardware for the I/P module, steering wheel module, SDM, front end sensors, seat belt pretensioners, and vehicle rollover sensor-Inspect for any damage and repair or replace each component as needed. * Passenger Presence System (PPS) for damage to the wiring or pressure system Accident With Side Air Bag Deployment - Component Replacement and Inspections After a collision involving side air bag deployment, replace the following components: * Inflatable restraint roof rail module, on the side of the impact. * Inflatable restraint side impact sensors (SIS) (front/rear), on the side of the impact * Inflatable restraint SDM * Seat belt pretensioner, on the side of impact. Perform additional inspections on the following components: * Mounting points or mounting hardware for the SIS, roof rail module (left/right), and seat belt pretensioner on the side of impact-Inspect for any damage and repair or replace each component as needed. * Mounting points or mounting hardware for the SDM and vehicle rollover sensor-Inspect for any damage and repair or replace each component as needed. Page 8534 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 14697 Shift Solenoid: Specifications 6L50/6L80/6L90 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Shift Solenoid Valve State and Gear Ratio Page 2199 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 10897 Page 11727 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 10083 6. Disconnect the EVAP vent solenoid pipe quick connect fitting (3) from the EVAP canister. 7. Remove the EVAP canister vent solenoid pipe clip (1) from the frame crossmember. 8. Disengage the retainer (1) securing the EVAP canister vent solenoid. 9. Slide the EVAP canister vent solenoid off the bracket towards the passenger side of the vehicle. 10. Remove the EVAP canister vent solenoid from the vehicle. Installation Procedure Page 2492 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 20240 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 8434 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 1020 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 15571 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 11344 Camshaft Position Sensor: Connector Views Engine Controls Connector End Views Camshaft Position (CMP) Sensor Page 14868 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 6881 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11853 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 12951 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 14866 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 12283 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 23026 - The ECM detects the analog cruise control switch input is out of the normal voltage range. TAC Inhibit - The ECM detects a fault within the throttle actuator control (TAC) system. TCS - The ECM detects that the traction control system had been activated. It is also possible that a tire with low air pressure can also set this disengagement reason. Trans. DTC - The ECM detects a transmission gear fault. Under Set Speed - The ECM detects that the vehicle speed is less than the cruise memory speed by more than a calibrated amount. VSES - The ECM detects that the vehicle stability enhancement system had been activated. Scan Tool Data List Scan Tool Data List The scan tool data lists contain all of the cruise control related parameters that are available on the scan tool. The parameters in the list are arranged in alphabetical order. The data list column indicates the location of the parameter within the scan tool menu selections. Use the scan tool data lists as directed by a diagnostic table or in order to supplement the diagnostic procedures. Begin all of the diagnostic procedures with Diagnostic System Check Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Use the scan tool data lists only after the following is determined: * There is no published DTC procedure nor published symptom procedure for the customer concern. * The DTC or symptom procedure indicated by the Diagnostic System Check does not resolve the customer concern. The typical data values are obtained from a properly operating vehicle under the conditions specified in the first row of the scan tool data list table. Comparison of the parameter values from the suspect vehicle with the typical data values may reveal the source of the customer concern. Page 21083 Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Replacement Hood Primary Latch Release Cable Replacement Page 5122 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16367 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 5333 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 16199 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 2409 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 12228 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 24242 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 21001 1. Install the door lower striker (2). 2. Install the spacer, if equipped. 3. Install the door lower striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. Notice: Refer to Fastener Notice. 5. Tighten the lower striker bolts. Tighten the door lower striker bolts to 24 N.m (18 lb ft). Page 8274 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 4941 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 10181 Air Flow Meter/Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 8276 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 16118 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 12174 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or greater. 6. Remove the TCC PCS retaining bolt and retaining bracket. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Page 2265 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 16766 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9259 Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 17051 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23148 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 10280 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 23947 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 19617 Memory Seat Module X7 (AN3) Page 18646 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 10545 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 11747 Camshaft Position Sensor: Connector Views Engine Controls Connector End Views Camshaft Position (CMP) Sensor Locations Ambient Temperature Sensor / Switch HVAC: Locations HVAC Component Views Ambient Air Temperature Sensors 1 - Radiator Core Support 2 - Ambient Air Temperature Sensor (DF5) 3 - Ambient Air Temperature Sensor - HVAC (CJ2) A/C - HVAC Control Module Lockup During Reprogramming Control Module HVAC: All Technical Service Bulletins A/C - HVAC Control Module Lockup During Reprogramming Bulletin No.: 06-01-39-014 Date: December 06, 2006 INFORMATION Subject: Information On HVAC Control Module Lockup During Reprogramming Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) The purpose of this bulletin is to alert technicians to a condition they may encounter while trying to reprogram a Heating, Ventilation and Air Conditioning (HVAC) control module. If the HVAC control module reprogramming event is interrupted, the control module may go into a "lock up" mode. This will cause the HVAC control module to disable communications and a second try at reprogramming will fail. The interruption may be caused by a software anomaly inside the HVAC control module. If the HVAC reprogramming event was interrupted and a subsequent reprogramming attempt fails, perform a battery reset. This can be accomplished by either removing and reinstalling the HVAC BATT fuse, located in the underhood fuse block, or by disconnecting and reconnecting the HVAC control module connector C2. Connector C2 is grey in color with 16 cavities. Once the battery reset has been performed, the HVAC control module will resume communications and will then be able to be reprogrammed. The Warranty Parts Center (WPC) has received HVAC control modules that have been returned and described as non-functional but were tested with no problems found. If the module has been replaced due to a failed second attempt at reprogramming caused by the lock up, the module will be returned and charged back to the dealer. Technicians must also remember that after a new HVAC control module has been installed into a vehicle, it must be programmed, otherwise it will not be functional. Disclaimer Page 16122 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 16410 X211 Inline Harness Connector End Views X211 Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) to Console Harness (Y91/UQA/D07) Page 17088 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 8304 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 2531 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 10505 Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service Disconnect Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Important: There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. * Bartholomew (1) * Q Release (2) * Squeeze to Release (3) * Sliding Retainer (4) * Push Down TI (5) The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except where indicated. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). Caution: Refer to Safety Glasses Caution. Notice: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice. 1. Using compressed air, blow any dirt or debris from around the connection. Page 9250 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Controls Connector End Views Engine Coolant Temperature (ECT) Sensor Page 21192 Drivetrain and Front Suspension Frame Front Crossmember Replacement (4WD 2500 HD, 3500) Drivetrain and Front Suspension Frame Front Crossmember Replacement (4WD 2500 HD, 3500) Page 5197 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 9278 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Drivetrain - Rear Drive Axle Whine Noise Slip Yoke: All Technical Service Bulletins Drivetrain - Rear Drive Axle Whine Noise Bulletin No.: 06-04-17-002A Date: January 12, 2007 TECHNICAL Subject: Rear Drive Axle Whine Noise (Replace Slip Yoke Assembly) Models: 2004-2007 Chevrolet Silverado (Classic) 1500 Series 2WD Crew Cab Models (C15543) 2004-2007 GMC Sierra (Classic) 1500 Series 2WD Crew Cab Models (C15543) Supercede: This bulletin is being revised to include additional model information. Please discard Corporate Bulletin Number 06-04-17-002 (Section 04 - Driveline/Axle). Condition Some customers may comment on a slight axle whine noise heard only at certain speeds, typically on coast conditions between 72-96 km/h (45-60 mph). Cause "Inherent" ring and pinion gear whine. All gear driven units, such as automotive rear axles, produce some level of noise that cannot be eliminated with conventional adjustments and repairs. "Inherent" axle noise can be described as a slight noise heard only at a certain speed (typically between 72-96 km/h (45-60 mph) on most General Motors(R) trucks). The presence of this noise is not indicative of a functional concern with the axle assembly. However, some customers may find that this inherent axle noise is unacceptable. Correction Using the service procedures in SI, replace the propshaft front slip yoke and u-joint with a tuned damper slip yoke with u-joint assembly, P/N 19151749, ONLY after diagnosis concludes that it is an "inherent" rear axle noise and no physical damage or incorrect adjustment exists. Do NOT replace the propshaft assembly. If the noise is not correctly diagnosed as "inherent" and having a peak in the narrow speed range of 72-96 km/h (45-60 mph), the addition of a tuned damper slip yoke and u-joint can aggravate the perceptible noise level. It is extremely important to first diagnose the rear axle noise as "inherent". Refer to the following diagnostic information and procedure for rear axle noise in SI: Diagnostic Starting Point - Rear Drive Axle Symptoms - Rear Drive Axle Rear Drive Axle Noises Noisy in Drive Parts Information Warranty Information Page 23854 Page 12192 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 6589 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 13773 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 12217 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 13646 1. Install the shift lever (1). Notice: Refer to Fastener Notice. 2. Install the shift lever bolt (2). Tighten the bolt to 20 N.m (15 lb ft). 3. Connect all electrical connectors. 4. Position the shift lever seal. 5. Install the steering column shroud. Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Disconnect the engine wiring harness electrical connector (4) from the crankshaft position (CKP) sensor. Page 6209 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 20138 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 10783 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 13614 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 15918 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 6479 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 7631 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 7418 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 12955 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 21219 Trailer Hitch: Service and Repair Trailer Hitch Replacement (Heavy Duty) Trailer Hitch Replacement (Heavy Duty) Removal Procedure 1. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 2. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 3. Remove the hitch platform bolts (6) from the frame weld nuts (2). 4. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Page 9292 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 2678 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 3902 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 171 Page 9118 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. A/C - HVAC Control Module Lockup During Reprogramming Control Module HVAC: All Technical Service Bulletins A/C - HVAC Control Module Lockup During Reprogramming Bulletin No.: 06-01-39-014 Date: December 06, 2006 INFORMATION Subject: Information On HVAC Control Module Lockup During Reprogramming Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) The purpose of this bulletin is to alert technicians to a condition they may encounter while trying to reprogram a Heating, Ventilation and Air Conditioning (HVAC) control module. If the HVAC control module reprogramming event is interrupted, the control module may go into a "lock up" mode. This will cause the HVAC control module to disable communications and a second try at reprogramming will fail. The interruption may be caused by a software anomaly inside the HVAC control module. If the HVAC reprogramming event was interrupted and a subsequent reprogramming attempt fails, perform a battery reset. This can be accomplished by either removing and reinstalling the HVAC BATT fuse, located in the underhood fuse block, or by disconnecting and reconnecting the HVAC control module connector C2. Connector C2 is grey in color with 16 cavities. Once the battery reset has been performed, the HVAC control module will resume communications and will then be able to be reprogrammed. The Warranty Parts Center (WPC) has received HVAC control modules that have been returned and described as non-functional but were tested with no problems found. If the module has been replaced due to a failed second attempt at reprogramming caused by the lock up, the module will be returned and charged back to the dealer. Technicians must also remember that after a new HVAC control module has been installed into a vehicle, it must be programmed, otherwise it will not be functional. Disclaimer Page 10250 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 21586 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 16742 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 5046 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 2872 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 11035 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 24727 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 5184 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 5401 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 11560 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 20921 Note Using the punch and hammer, strike the rounded end of the roll pin to loosen the roll pin. The head of the roll pin should protrude from the handle housing. Remove the roll pin with pliers as shown in the illustration. 3. Using a punch, hammer, and pliers, remove the roll pin from the inside door handle. 4. Discard the roll pin. 5. Install the new roll pin that is included in the door handle kit, P/N 88880051. 6. Install the front side door inside handles. Refer to Front Side Door Inside Handle Replacement in SI. Rear Side Door Inside Handle Replacement 1. Remove the driver and passenger rear side door inside handles. Refer to Rear Side Door Inside Handle Replacement in SI. 2. Place rear side door inside handles on a work bench. Note Using a punch and hammer, strike the rounded end of the roll pin to loosen the roll pin. The head of the roll pin should protrude from the handle housing. Remove the roll pin with pliers as shown in the illustration. 3. Using a punch, hammer, and pliers, remove the roll pin from the inside door handle. 4. Discard the roll pin. Page 11224 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 6475 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 17108 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 13680 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Page 21569 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 13554 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 9390 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Page 3207 Page 12638 Page 1953 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12649 Roof Beacon Relays Hazard Flasher Relay: Diagrams Roof Beacon Relays Power and Grounding Connector End Views Roof Beacon Relay (TRW) Page 9111 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Audio System - Static/Ignition Noise on AM Band Ignition Cable: Customer Interest Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Page 6587 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 24181 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 20984 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-004 Date: 070228 Body - Water Leaks Into Rear Footwell Area Bulletin No.: 07-08-64-004 Date: February 28, 2007 TECHNICAL Subject: Wet or Stained Carpeting in Rear Footwell After Heavy Rainfall or Car Wash (Replace Water Deflector) Models: 2007 Chevrolet Silverado Extended Cab (New Body Style) 2007 GMC Sierra Extended Cab (New Body Style) Condition Some customers may comment on wet or stained carpeting in the rear footwell after a very heavy rainfall or high pressure car wash. Cause This condition may be caused by a void in the loft area around the map pocket on the TIAS water protector (water deflector) inside the door trim. This loft area normally creates an interference condition, causing the adhesive bead to wet out and seal off the water. When a void is present, water intrusion may occur. Correction Carefully remove the interior rear side door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9 or SLT) in SI. Page 13675 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat-bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 6. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). Page 9582 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 5056 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 8783 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 6274 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 7976 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 6534 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Allison - Automatic Transmission Fluid Pan: Service and Repair Allison - Automatic Transmission Oil Pan Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Important: It would be helpful to record the amount of transmission fluid lost during this procedure. Fluid in good condition, drained into a clean container, may be reused. 2. Remove the drain plug (7) and drain plug seal (6) from the oil pan (5). Allow the fluid to drain into a suitable container. 3. Inspect the drained fluid. 4. Remove 12 bolts (8). Hold the oil pan in position as the last bolt is removed. 5. Remove oil pan (5) and gasket (3). 6. Inspect magnet (4). Excessive metallic particles or large metallic particles may indicate need for overhaul or replacement of the transmission. Important: DO NOT remove the transmission internal oil filter or seal if only replacing the oil pan or oil pan gasket. 7. Remove the transmission internal oil filter (2) by pulling straight down where the suction tube is seated in the transmission case. 8. Remove the transmission internal oil filter seal (1) from the filter or from the seal bore in the transmission case. Discard the old seal. Discard the filter, if the filter is being replaced. Installation Procedure 1. Remove all gasket material from the transmission case. Remove any scratches from the transmission case that would cause a split-line leak. 2. Place a new seal (1) on the tube of the transmission internal oil filter (2), if the filter was removed. Be sure the seal locates against the shoulder on the internal oil filter tube. 3. Push the filter (2) and seal (1) into the seal bore in the transmission case. Position the transmission internal oil filter properly. 4. Install 2 headless guide bolts (9), M8 x 1.25, into opposite corners of the oil pan mounting face on the transmission case. 5. Place a gasket (3) on the oil pan and align the bolt holes. 6. Slide the gasket (3) and oil pan (5) over the guide bolts and hold them in place while installing 2 bolts (8) to hold the parts in place. Notice: Refer to Fastener Notice. 7. Remove the guide bolts. 8. Install the 10 remaining oil pan bolts (8). Tighten the bolts to 27 N.m (20 lb ft). Page 14985 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 2664 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 9224 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 7053 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 11565 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Navigation Radio - Weak Or No GPS Signal Information Navigation System: All Technical Service Bulletins Navigation Radio - Weak Or No GPS Signal Information INFORMATION Bulletin No.: 08-08-44-027 Date: August 12, 2008 Subject: Information on Navigation Radios that Have a Weak or No GPS Signal Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models with Navigation Radios Some customers may comment on intermittent or no Global Positioning System (GPS) signal reception on the Navigation radio. The GPS signal reception icon on the map screen may have a red line through it. This condition may be caused by aftermarket electronic devices such as radar detectors, cell phones, and MP3 players that may interfere with the GPS signal reception. Aftermarket window tinting or clear UV film applied to the windshield may also reduce the GPS signal reception and cause the Navigation radio to function incorrectly. Recommendations Educate the customer on the GPS antenna location and the need to keep electronic devices away from it. The GPS antenna is located in the upper center of the Instrument Panel. Instruct the customer to move electronic devices away from the GPS antenna. It may also be necessary to remove aftermarket films and tinting from the windshield. Do not replace a Navigation radio that seems to have poor GPS signal reception without considering these possible causes of the concern. Refer to the No Global Positioning System (GPS) Reception diagnostic procedure in SI for more information. Disclaimer Page 1007 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 14876 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 266 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 4383 Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 12222 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 3084 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 11266 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 13419 Transmission Output Shaft Seal Replacement Transmission Output Shaft Seal Replacement Page 11836 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Page 6305 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 2354 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Electrical - Various Electrical Malfunction/Systems Inop Trailer Warning Indicator: All Technical Service Bulletins Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 10260 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 11579 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Page 23147 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 17019 1 - G111 (XA7) 2 - G108 3 - G110 (XA7) 4 - Brake Booster Assembly 5 - Fuse Block - Underhood 6 - G104 (6A6) Below the I/P Page 17313 X220 Inline Harness Connector End Views X220 Brake Clutch Harness to Chassis Harness (JL1) X224 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0/5X7) Page 1849 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 6663 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Interior - Elimination Of Unwanted Odors Carpet: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 12597 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 10241 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 19123 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Body - Outside Door Handle(s) Squeak When Operated Front Door Exterior Handle: All Technical Service Bulletins Body - Outside Door Handle(s) Squeak When Operated TECHNICAL Bulletin No.: 08-08-64-007 Date: May 13, 2008 Subject: Squeaky Outside Door Handle (Grease U-Channel of Handle) Models: 2007-2008 Cadillac Escalade, Escalade EXT, Escalade ESV 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Condition Some customers may comment on a squeak noise coming from the door handle as the handle is actuated. Cause This condition may be caused by the pin and the inside of pawl surface making contact with each other, resulting in a squeak noise. Correction DO NOT REPLACE THE DOOR HANDLE. 1. Remove the fasteners to the door handle, leaving the rod to the latch attached. 2. Apply a generous amount of dielectric silicone grease, P/N 12345579 (in Canada, 10953481), as shown in the graphics, into the U-channel of the handle between the pawl and the tower where the gray pin enters through the spring and the pawl. 3. Cycle the handle at least 20 times to work the grease around the pin and to make sure that the squeak has been eliminated. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 130 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 1845 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 6482 View of the connector when released from the component. View of another type of Micro 64 connector. Page 15905 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14736 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 9853 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Brakes - Aftermarket Trailer Brake Controllers Trailer Brake Control Module: All Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 15259 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Page 6237 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 6220 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 23273 Parts Information Warranty Information For IP clusters replaced/programmed due to customer satisfaction concerns of poor backlighting, the warranty claim MUST be submitted using the labor operation listed in this bulletin. Disclaimer Page 14185 19. Remove the pinion. 20. Remove the collapsible spacer. 21. Remove the inner pinion bearing from the pinion using the J 22912-B and a hydraulic press. 22. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. Page 14265 7. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing. 8. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2). 9. Push the flange of the axle shaft (1) toward the differential. 10. Remove the C-lock (4) from the button end of the axle shaft (1). Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make the assembly difficult. 11. Remove the axle shaft (1) from the housing (5). Locations Power Door Lock Switch: Locations Vehicle Access Component Views Driver Door 1 - Door Frame 2 - Window Switch - Driver (A31 -AN3/DL3) 3 - Outside Rearview Mirror - Driver 4 Memory/Heated Seat Switch (AN3) 5 - Outside Rearview Mirror Switch (DL8/DPN) 6 - Driver Door Switch (DDS) (AN3/DL3) 7 - Speaker - Left Front 8 - Window Motor - Driver (A31) 9 - Door Lock Switch - Driver (AU3 -AN3/DL3) 10 - Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) 11 - Door Latch Assembly - Driver Passenger Door Page 6533 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 7322 Vehicle Zoning Strategy Truck Zoning Page 1260 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 8630 Oxygen Sensor: Connector Views Engine Controls Connector End Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Page 15339 Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JD9) Page 11761 Service and Repair Windshield Washer Reservoir: Service and Repair Windshield Washer Solvent Container Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the left front wheel assembly. 3. Remove the left front wheelhouse liner. 4. Remove the lower outer bolt (1) from the washer container prior to lowering the vehicle. 5. Disconnect the washer pump hoses (1, 2) from the left side fender flange. 6. Drain the windshield washer solvent into a suitable container. 7. Disconnect the electrical connectors. 8. Lower the vehicle in order to access the hood latch. 9. Open the hood. Page 9314 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 16756 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 1663 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 5111 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 2657 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 17182 Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Page 18623 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P C4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Lighting Systems Connector End Views Ambient Light Sensor: Diagrams Lighting Systems Connector End Views Lighting Systems Connector End Views Ambient Light Sensor (C67/C42) Page 7117 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 23896 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 13839 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 15572 Trailer Brake Control Module: Diagrams Trailer Brake Controller Module (TBCM) Electronic Suspension Control (ESC) Module Page 2359 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 24621 Wiper Blade: Testing and Inspection Wiper Blade Element Check 1. Remove the wiper blades from the wiper arms. 2. Look down the length of the blade element. 3. Replace the wiper blade if the rubber element which contacts the glass is not on the centerline of the blade +/-15 degrees. 4. Install the wiper blades on the wiper arms. Page 949 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Diagrams Lateral Accelerometer: Diagrams Yaw Rate and Lateral Acceleration Sensor (JL4) Yaw Rate and Lateral Acceleration Sensor (JL4) Page 10849 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Locations Yaw Rate Sensor: Locations Antilock Brake System Component Views Under the Front Seats 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) Page 2194 Page 6348 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 14665 Clutch Control Solenoid Valve: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 15886 View of the connector when released from the component. View of another type of Micro 64 connector. Page 9375 Page 12346 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten the bolts in the sequence shown to 11 N.m (97 lb in). 15. Ensure that the manual detent spring is aligned properly with the detent lever. A/C - Does Not Cool/Can't Change Mode/DTC's Set Multiple Junction Connector: All Technical Service Bulletins A/C - Does Not Cool/Can't Change Mode/DTC's Set Bulletin No.: 07-01-38-009B Date: November 28, 2007 TECHNICAL Subject: EI07264 - Manual HVAC, Temperature or Mode Actuator Performance, A/C Does Not Cool, Unable to Change Mode, DTC B0228, B0413, B0423, B0433, B3779, B3782 (Diagnose for Intermittent Wiring Connection at RH BEC) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Extended and Crew Cab Models Only with Manual Temperature Control HVAC System (RPO C67) Supercede: This bulletin is being revised to end the need for engineering information and to provide diagnostic procedures to accurately diagnose this condition. Please discard Corporate Bulletin Number 07-01-38-009A (Section 01 - HVAC). Condition This concern only applies to Extended or Crew cab vehicles. If the customer did not bring their vehicle in for this concern, do no proceed with this bulletin. Some customers may comment that the A/C blows hot air or is inoperative. They may also comment that they are unable to change the temperature or HVAC mode of the vehicle. Under these conditions, the actuator has moved to a default position. Refer to the table. Cause Page 10610 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 2062 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 5051 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 6821 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 10214 View of the connector when released from the component. View of another type of Micro 64 connector. Page 5022 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 12165 Shift Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams 6L50/6L80/6L90 - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Allison - Automatic Transmission Control Module: Service and Repair Allison - Automatic Transmission Transmission Control Module Replacement Page 5439 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 9727 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 3082 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 2832 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 7511 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure Important: Prior to removing the spark plug wire(s) note the correct routing of the wires as required. 1. Remove the appropriate spark plug wire boot(s) (1, 2) from the ignition coil. 1. Twist the spark plug boot 1/2 turn. 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose, in order to remove the spark plug wire boot from the ignition coil. 2. Remove the appropriate spark plug wire boot(s) (2) from the spark plug. (left side shown, right similar). 1. Twist the spark plug boot 1/2 turn. Page 10226 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 7565 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21692 Driver Door Switch (DDS) X3 (AN3/DL3) Page 16989 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 3104 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 9900 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 22938 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 4.5 quarts (4.3 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 3309 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 11707 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 12705 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9299 View of the connector when released from the component. View of another type of Micro 64 connector. Page 10896 Page 21317 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Page 10443 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 6495 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 13044 19. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 4070 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 19713 Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 12577 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 23137 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 4486 1. Install the J 23523-F plate and bolts onto the crankshaft balancer. Tighten the bolts to 25 N.m (18 lb ft). 2. Install the J 23523-F forcing screw into the plate. 3. Rotate the J 23523-F forcing screw clockwise in order to remove the crankshaft balancer. 6. Remove the J 23523-F from the crankshaft balancer. 7. Note the position and length of any crankshaft balancer weights, if necessary. 8. Clean and inspect the crankshaft balancer, if necessary. Refer to Crankshaft Balancer Cleaning and Inspection. Installation Procedure 1. Apply a small amount of grease to the crankshaft front cover seal sealing surface if reusing the seal. Important: The length and location of the weight(s) must be the same as the original. 2. Ensure that the crankshaft balancer weight(s) is installed in the proper location, if necessary. Notice: The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer. 3. Apply a small amount of adhesive into the crankshaft balancer keyway in order to seal the crankshaft balancer keyway and crankshaft joint. Refer to Sealers, Adhesives, and Lubricants for the correct part number. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 2841 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 20408 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components Refer to SIR Identification Views. There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. Page 2056 View of the connector when released from the component. View of another type of Micro 64 connector. Page 21866 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 14076 Valve Body: Service and Repair Allison - Automatic Transmission Control Valve Body Replacement Tools Required * J 44247 Internal Wiring Harness Installer * J 44257 Main Wiring Harness Connector Remover Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the external wiring harness from the transmission main connector. Use J 44257 if the connector is not easily accessible. 2. Remove the oil pan and transmission internal oil filter. Important: The transmission main connector is actually one end of the internal harness that protrudes through the transmission case. 3. Place a 30 mm (1 3/16 in) 12-point deep socket or box-end (2) over the connector (1). 4. Push inward on the socket or wrench to release the retainer feet that attach the connector (1) to the transmission case. 5. Remove the wrench. Push inward on the electrical connector to separate it from the transmission case. This allows the internal wiring harness to remain with the control valve assembly when removed. Page 6522 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 9216 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 17697 Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir Replacement - Off Vehicle Disassembly Procedure 1. Remove the power steering pump assembly from the vehicle. 2. Remove the power steering fluid reservoir studs (2) from the power steering pump assembly (1). 3. Remove the power steering pump fitting (4). 4. Remove the power steering pump fitting seal (3). 5. Remove the power steering pump flow control valve (2) and the power steering pump flow control valve spring (3) from the power steering pump assembly (1). 6. Separate the power steering fluid reservoir (1) and the power steering pump (2). Page 21576 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 21322 Disclaimer Page 13507 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Disable the SIR system. 2. Remove the knee bolster. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Resonator Replacement Removal Procedure 1. Disconnect the positive crankcase ventilation (PCV) hose (1) from the air cleaner outlet resonator. 2. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 3. Loosen the air cleaner outlet resonator clamp (2) at the throttle body. 4. Remove the air cleaner outlet resonator from the throttle body and the MAF/IAT sensor. Installation Procedure Page 8020 Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Locations Parking Brake Warning Switch: Locations Hydraulic Brake Component Views 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Page 12974 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 6131 Page 21848 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 17439 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 21242 Page 6270 Page 8466 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 22370 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 8252 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 9286 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 5317 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 12251 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 13815 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 2759 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 5000 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 16945 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 8003 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 3910 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 10998 Page 10324 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Page 10270 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Interior - Lint Accumulation On Ebony Colored Seats Head Rest: All Technical Service Bulletins Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 24541 2. Remove the front compartment side sight shield on the passenger's side of the engine compartment (1). Refer to Front Compartment Side Sight Shield Replacement in SI. Note The underhood fuse block is located in the engine compartment on the passenger side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 3. Locate the underhood bussed electrical center (UBEC) (2). 4. Remove the UBEC cover (2) and locate the WSW/HTR 60 amp heated windshield washer fuse. 5. Remove the WSW/HTR 60 amp heated windshield washer fuse (3) using pliers. 6. Discard the WSW/HTR 60 amp heated windshield washer fuse (3). 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 10. Install the front compartment side sight shield on the passenger's side of the engine compartment (1). Refer to Front Compartment Side Sight Shield Replacement in SI. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Page 11496 8. Install the engine wiring harness clips (1, 2) to the engine harness brackets. 9. Connect the engine wiring harness electrical connector (1) to the fuel meter body. 10. Install the engine wiring harness CPA retainer at the fuel meter body. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 12964 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 23390 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Interior - Front Seat Cushion Cover Becomes Detached Seat Cover: Customer Interest Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Page 15170 Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JH6/JH7) Wheel Speed Sensor (WSS) - Right Front (JH6/JH7) Page 11852 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 8962 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Diagram Information and Instructions Door Module: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 2331 Oxygen Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 13758 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 7429 4. Position the knock sensor heat shield to the engine block and install the bolt. Tighten the bolt to 10 N.m (89 lb in). 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. Page 22381 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 12372 Transmission Mode Switch: Locations Shift Lock Control Component Views Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 8923 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 21547 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 20529 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Page 20092 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 8216 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 23256 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 21540 Page 6454 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Diagrams Power Window Relay: Diagrams Window Systems Connector End Views Sliding Rear Window Close Relay (A48) Sliding Rear Window Open Relay (A48) Page 10977 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8913 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 12993 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 10838 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 12851 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 10132 * The areas surrounding the connections Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap. Trailer Hitch Replacement (Light Duty) Trailer Hitch: Service and Repair Trailer Hitch Replacement (Light Duty) Trailer Hitch Replacement (Light Duty) Removal Procedure 1. Disconnect the trailer wiring harness connector (3) from the trailer wiring recepticle (4). 2. Remove the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 3. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 4. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 5. Remove the hitch platform bolts (6) from the frame weld nuts (2). 6. Remove the hitch platform from the vehicle. Installation Procedure Page 12387 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 9931 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 5155 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 21061 5. Install the rear sliding window pulley (1). 1. Align the tabs (2) on the pulley (1) with the notch in the frame (3). 2. Turn the pulley downward, locking the pulley into the frame (3). 6. Install the regulator cables (2) to the retainers (1) across the bottom edge of the window frame. Page 2110 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 21057 Important: Use a suitable tool to release the tabs (1) from the rear sliding window pulley (3). 4. Remove the rear sliding window pulley covers (2). 5. Remove the regulator cables (2) from the retainers (1) located across the bottom edge of the window frame. 6. Remove the screw (1) from regulator (2). 7. Remove the regulator (2) from the motor/module. Page 15401 Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4) Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4) Page 13968 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Locations Turn Signal Switch: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 14125 5. Inspect the wiring harness near the data link resistor, between the truck box and frame for chafed/shorted wiring as shown. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > Data Link Resistor in SI. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Disconnect the electrical connector from the data link resistor. 7. Test the resistor for 110-130ohm. ‹› If not within the specified range, replace the data link resistor. ‹› If within the specified range, refer to Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. 8. Connect the electrical connector to the data link resistor. Secure the resistor as needed. 9. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 10. Lower the vehicle. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 12. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Inspection of Engine Harness Connector X109 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X109 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X109 in SI. 4. Before disconnecting, verify the connector is fully seated together even though the lever is locked down as shown. If the connector is not fully seated, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Connector Repairs in SI. 5. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Connector X115 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. Page 15405 Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) Rear Brake Hose Replacement (Frame to Axle - JH6, JH7) Page 10810 View of the connector when released from the component. View of another type of Micro 64 connector. Page 21270 For vehicles repaired under warranty, use the table. Disclaimer Page 6993 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 4965 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 4841 10. Remove the water pump bolts. 11. Remove the water pump. 12. Remove and discard the water pump gaskets. 13. Clean and inspect the water pump, if necessary. Refer to Water Pump Cleaning and Inspection. Installation Procedure 1. If reusing the old fasteners, apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent to the threads of the water pump bolts. 2. Install NEW water pump gaskets and the water pump. Notice: Refer to Fastener Notice. 3. Install the water pump bolts. Tighten the bolts to 45 N.m (33 lb ft). 4. Using J 41240, hold the water pump pulley, install the water pump pulley bolts. Tighten the bolts to 25 N.m (18 lb ft). Page 1204 Inflatable Restraint Sensing and Diagnostic Module (SDM) (10 Series -ASF) Page 20209 Parking Assist Control Module: Locations Object Detection Component Views Under the Front Seats 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Procedures Fluid - Differential: Procedures Rear Axle Lubricant Level Inspection (8.6 Inch Axle) Rear Axle Lubricant Level Inspection (8.6 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". 7. Insert the pipe cleaner into the fill plug opening with the stem facing down. 8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The distance between the bend and the lubricant level should be 15-40 mm (0.6-1.6 in). 9. If the measurement is greater than 40 mm (1.6 in), add lubricant until the level is between 15-40 mm (0.6-1.6 in) from the bottom edge of the fill plug hole. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Notice: Refer to Fastener Notice. 10. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 11. Lower the vehicle. Rear Axle Lubricant Level Inspection (11.5 Inch Axle) Rear Axle Lubricant Level Inspection (11.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. A/C - HVAC Control Module Lockup During Reprogramming Control Module HVAC: All Technical Service Bulletins A/C - HVAC Control Module Lockup During Reprogramming Bulletin No.: 06-01-39-014 Date: December 06, 2006 INFORMATION Subject: Information On HVAC Control Module Lockup During Reprogramming Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) The purpose of this bulletin is to alert technicians to a condition they may encounter while trying to reprogram a Heating, Ventilation and Air Conditioning (HVAC) control module. If the HVAC control module reprogramming event is interrupted, the control module may go into a "lock up" mode. This will cause the HVAC control module to disable communications and a second try at reprogramming will fail. The interruption may be caused by a software anomaly inside the HVAC control module. If the HVAC reprogramming event was interrupted and a subsequent reprogramming attempt fails, perform a battery reset. This can be accomplished by either removing and reinstalling the HVAC BATT fuse, located in the underhood fuse block, or by disconnecting and reconnecting the HVAC control module connector C2. Connector C2 is grey in color with 16 cavities. Once the battery reset has been performed, the HVAC control module will resume communications and will then be able to be reprogrammed. The Warranty Parts Center (WPC) has received HVAC control modules that have been returned and described as non-functional but were tested with no problems found. If the module has been replaced due to a failed second attempt at reprogramming caused by the lock up, the module will be returned and charged back to the dealer. Technicians must also remember that after a new HVAC control module has been installed into a vehicle, it must be programmed, otherwise it will not be functional. Disclaimer Page 4289 Disclaimer Page 23946 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 11423 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Locations Battery Current Sensor: Locations Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor Page 4686 Important: The intake manifold must be installed and the fasteners tightened while the adhesive is still wet to the touch. 3. Apply a 5 mm (0.197 in) bead of adhesive to the front top of the engine block. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 4. Extend the adhesive bead 13 mm (0.50 in) up onto each intake manifold gasket. 5. Apply a 5 mm (0.197 in) bead of adhesive to the rear top of the engine block. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 6. Extend the adhesive bead 13 mm (0.50 in) up onto each intake manifold gasket. 7. Install the intake manifold. 8. If reusing the old fasteners, apply threadlock to the threads of the intake manifold - lower bolts. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 9. Install the intake manifold - lower bolts. Page 10039 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 20806 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16013 Fuse Block - I/P, Device Usage Left I/P Junction Block Page 8409 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 2997 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 513 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 9865 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 14762 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11750 Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CMP sensor, install a NEW O-ring seal onto the sensor. 2. Install the CMP sensor to the wiring harness jumper. 3. Connect the CMP sensor wiring harness jumper to the CMP sensor. 4. Lubricate the O-ring seal with clean engine oil. 5. Install the CMP sensor and wiring harness jumper to the engine front cover. Notice: Refer to Fastener Notice. 6. Install the CMP sensor bolt. Tighten the bolt to 10 N.m (89 lb in). 7. Install the water pump. 8. Connect the engine wiring harness electrical connector (7) to the CMP sensor wiring harness jumper. Page 8755 Body Control Module (BCM) X7 Page 21505 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Regular Cab) Body Lock Pillar Trim Replacement (Regular Cab) 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Pressure Manual Valve Position Switch Logic Transmission Fluid Pressure Manual Valve Position Switch Logic Page 11935 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 9110 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 24330 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 2920 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 10225 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 16697 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 11093 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23525 Trailer Brake Control Panel Switch Page 17469 The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. When releasing the park brake pedal with the park brake release lever/handle, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. Correction If the symptoms match those listed above, or if a condition is found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202), then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: Visually inspect the IP harness for damage at the park brake pedal assembly (refer to potential damage points in photos - at the side and rear of the park brake assembly). Note that damage may be hidden from view (turned away from you, or covered by electrical tape). Operate the park brake release lever. Is the moving part at the end of the park brake release cable coming into contact and damaging the IP harness? Inspect the IP harness at this point. Note that the damage may be hidden from view (by electrical tape). If damage is found, repair the wiring. Page 14597 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 8139 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 21867 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 11211 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 24677 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 23194 For vehicles repaired under warranty, use the table. Disclaimer Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: All Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 1882 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 23314 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 21922 Memory Seat Module X5 (AN3) Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Page 14378 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12803 Page 12737 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 21193 Page 4916 View of the connector when released from the component. View of another type of Micro 64 connector. Page 934 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Instruments Nav. Radio Clock/Clock Tab Malfunctions Clock: All Technical Service Bulletins Instruments Nav. Radio Clock/Clock Tab Malfunctions Bulletin No.: 08-08-44-002 Date: February 15, 2008 TECHNICAL Subject: Navigation Radio Clock and/or Clock Tab Do Not Appear or Disappears Intermittently (Update Navigation Radio with New Software) Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008 HUMMER H2 with Radio RPO UVB or U3U Condition Some customers may comment that the clock and/or the clock tab does not appear on the navigation screen. Cause This condition may be caused by a software anomaly, which causes the clock and/or clock tab to disappear during the ignition key cycle. Correction DO NOT REPLACE THE NAVIGATION RADIO. Using the Tech 2(R), verify that the vehicle is equipped with one of the following radio part numbers: If the vehicle is not equipped with one of the following radio part numbers, disregard this bulletin. 15882766 15882767 15940102 15940103 25797978 25834072 Update the Navigation Radio's software to correct this condition. This software upgrade will also update some operating characteristics on the Navigation Radio. The following functions or displays may be affected: Inform the customer that stored destinations and radio presets may not be retained during programming. clock font size text color on light colored screens split screen icon to minimize the "Points of Interest" popup and "Exit" popup change driver locked out features when the vehicle is out of "Park" "back" button on street address entry screen for entering street number How to Obtain Nav Software Update Disc (P/N 25956121 - software version 0B92): Software discs are available through the GM Nav Disc Center. Dealers should retain the disc for use in repairing future vehicles. DO NOT give the software disc to the customer. Page 24701 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 15899 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 21389 Console: Service and Repair Floor Console Bezel Replacement Floor Console Bezel Replacement Page 11013 Page 614 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 10528 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Circuit/System Verification Important: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. Ignition ON, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. ‹› If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 1. Ignition OFF, all accessories OFF, install the CH-48027. Refer to Fuel Pressure Gage Installation and Removal. See: Fuel Pressure Gage Installation and Removal 2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Important: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Restricted or plugged fuel filter * Restricted or plugged strainer * Stuck or binding fuel level float * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel Page 18003 Page 24252 Vanity Lamp: Connector Views Lighting Systems Connector End Views Sunshade - Left (DH6) Sunshade - Right (DH6) Page 13575 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 17061 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 10529 pressure should stabilize and remain constant. 1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 3. Remove the J 37287 and CH-48027. 4. Operate the vehicle within the conditions of the customers concern while monitoring the fuel trim and O2 parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 5. If the fuel system components test normal, refer to Symptoms - Computers and Control Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Fuel Injector Replacement * Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Page 7531 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Page 9096 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 73 Disclaimer Page 22114 Memory Seat Module X3 (AN3) Diagrams Hazard Warning Switch: Diagrams Power and Grounding Connector End Views Roof Beacon Relay (TRW) Page 8101 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 11074 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 3556 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose in order to remove the spark plug wire boot from the spark plug. 3. Open the spark plug wire separators (1). 4. Remove the appropriate spark plug wire(s). Installation Procedure Notice: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 1. If reinstalling the old spark plug wires, apply dielectric grease GM PN 12345579 (Canadian PN 10953481), or equivalent to the inside the spark plug wire boots. 2. Install the appropriate spark plug wire(s) 3. Close the spark plug wire separators (1). 4. Install the appropriate spark plug wire boot(s) (2) to the spark plug. (left side shown, right similar). Page 21888 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 21575 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 12000 Spark Plug: Application and ID Spark Plug Type................................................................................................................................... ................GM P/N 126078234 AC Delco P/N 41-993 Page 11067 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20160 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 13232 6. Remove the cooling lines from the transmission. 7. Remove the oil cooling lines from the vehicle. Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Install the cooling lines to the transmission. 3. Install the engine protection shield. 4. Lower the vehicle. 5. Install the transmission fluid cooler hose to the radiator. 6. Install the transmission fluid cooler hose to the Auxiliary oil cooler. 7. Install the front grill assembly. Page 4701 3. If required, install a NEW MAP sensor seal. Apply a small drop of clean engine oil to the seal. 4. Install the MAP sensor. 5. If required, install a NEW throttle body gasket. 6. Install the throttle body. 7. Install the rear throttle body stud. If reusing the old stud, apply threadlock to the threads. Refer to Sealers, Adhesives, and Lubricants for the correct part number. Tighten the stud to 9 N.m (80 lb in). 8. If required, install a NEW O-ring seal to the PCV cover. Apply clean engine oil to the seal. 9. Install the PCV valve cover. 10. If required, install a NEW O-ring seal. Apply clean engine oil to the seal. 11. Install the power brake booster vacuum fitting. Diagrams Brake Booster Vacuum Sensor: Diagrams Brake Booster Vacuum Sensor (JL4) Brake Booster Vacuum Sensor (JL4) Page 7179 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Recall 08V441000: Washer Fluid Heater Overheating Washer Fluid Heater: Recalls Recall 08V441000: Washer Fluid Heater Overheating MAKE/MODELS: MODEL/BUILD YEARS: Buick/Enclave 2008 Buick/Lucerne 2006-2008 Cadillac/DTS 2006-2008 Cadillac/Escalade 2007-2008 Cadillac/Escalade ESV 2007-2008 Cadillac/Escalade EXT 2007-2008 Chevrolet/Avalanche 2007-2008 Chevrolet/Silverado 2007-2008 Chevrolet/Suburban 2007-2008 Chevrolet/Tahoe 2007-2008 GMC/ Acadia 2007-2008 GMC/Sierra 2007-2008 GMC/Yukon 2007-2008 GMC/Yukon XL 2007-2008 Hummer/H2 2006-2008 Saturn/Outlook 2007-2008 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: August 27, 2008 NHTSA CAMPAIGN ID NUMBER: 08V441000 NHTSA ACTION NUMBER: EA08010 COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 857735 SUMMARY: GM is recalling 857,735 M/Y 2006-2008 Buick Lucerne; Cadillac DTS; Hummer H2; M/Y 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL, Saturn Outlook; and M/Y 2008 Buick Enclave vehicles equipped with a heated wiper washer fluid system. A short circuit on the printed circuit board for the washer fluid heater may overheat the control-circuit ground wire. CONSEQUENCE: This may cause other electrical features to malfunction, create an odor, or cause smoke increasing the risk of a fire. REMEDY: Dealers will install a wire harness with an in-line fuse free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact Buick at 1-866-608-8080; Cadillac at 1-800-982-2339 or http://www.cadillac.com; Chevrolet at 1-800-630-2438; Saturn at 1-800-972-8876 or http://www.saturn.com, GMC at 1-866-996-9436; or Hummer at 1-800-732-5493; or mygmlink at http://www.gm.com/recall. NOTES: GM recall No. 08048. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Locations Ambient Light Sensor: Locations Lighting Systems Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 10408 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 17924 Disclaimer Page 2973 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Diagrams Steering Mounted Controls Assembly: Diagrams Secondary/Configurable Control Connector End Views Steering Wheel Control Switch Assembly - Left (K34/KA9) Steering Wheel Control Switch Assembly - Right (UK3) Page 11378 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 24509 11. Connect the large two-wire connector (1) to the body harness (2). 12. Connect the small five-wire connector (1) to the body harness (2). 13. Secure the large two-wire connector and small five-wire connector to the windshield washer solvent heater assembly bracket. 14. Connect the two windshield wiper solvent inlet and outlet hoses together. Use a portion of the rubber wiper solvent hose removed in Step 1 if needed to join the two plastic wiper solvent hoses together. Discard the remaining portions of the rubber windshield wiper solvent hoses. 15. Route and secure windshield wiper solvent hose along passenger side front fender. Page 16136 Page 7271 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 12074 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 22130 Memory Seat Module X5 (AN3) Page 1030 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 18717 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History screen (dealers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure 1. If the vehicle is equipped with vinyl flooring and no cutout flap under the driver's seat, no further action is required. For all other vehicles, proceed to Step 2. Note Driver seat removal is NOT required for crew cab or extended cab vehicles. Certain 2009 regular cab vehicles built after approximately March 1, 2009 with carpet that has a 2-sided cutout over the SDM, however, will require driver seat removal. Refer to Front Seat Replacement-Bucket in SI. After the seat removal, proceed to Step 2 in the bulletin. Regular cab vehicles with carpet that has a 3-sided cut over the SDM do NOT require seat removal. Page 22439 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 10900 Vehicle Zoning Strategy Truck Zoning Page 5086 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 9890 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 2217 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 4133 Junction Block - Left I/P X13 (AN3) Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: All Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Page 19378 Front Seat Cushion Center Cover Replacement Seat Cushion: Service and Repair Front Seat Cushion Center Cover Replacement Front Seat Cushion Center Cover Replacement Page 16076 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 884 Body Control Module (BCM) X3 Page 21832 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 23881 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: Customer Interest Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 7186 Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CMP sensor, install a NEW O-ring seal onto the sensor. 2. Install the CMP sensor to the wiring harness jumper. 3. Connect the CMP sensor wiring harness jumper to the CMP sensor. 4. Lubricate the O-ring seal with clean engine oil. 5. Install the CMP sensor and wiring harness jumper to the engine front cover. Notice: Refer to Fastener Notice. 6. Install the CMP sensor bolt. Tighten the bolt to 10 N.m (89 lb in). 7. Install the water pump. 8. Connect the engine wiring harness electrical connector (7) to the CMP sensor wiring harness jumper. Page 2826 Page 18228 Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Page 23364 Parts Information Warranty Information For IP clusters replaced/programmed due to customer satisfaction concerns of poor backlighting, the warranty claim MUST be submitted using the labor operation listed in this bulletin. Disclaimer Page 12285 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 12682 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 18153 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 12038 Shift Interlock Solenoid: Diagrams Shift Lock Control Connector End Views A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid Locations Sunroof / Moonroof Switch: Locations Sunroof Component Views Front Headliner Components 1 - Inside Air Temperature Sensor - Front (CJ2) 2 - Cellular Microphone (UE1/U3U/UVB) 3 Courtesy/Reading Lamps - Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade - Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly 8 - Inside Rearview Mirror (ISRVM) 9 - Courtesy/Reading Lamps - Front 10 - Windshield 11 - Sunshade - Left (DH6) Service and Repair Global Positioning System Antenna: Service and Repair Global Positioning System (GPS) Antenna Replacement Page 18085 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 1085 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Air Inlet Grille Panel Replacement Wiper Motor: Service and Repair Air Inlet Grille Panel Replacement Air Inlet Grille Panel Replacement Page 11392 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 6779 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 10843 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 13252 Fluid Pressure Sensor/Switch: Specifications Allison - Automatic Transmission Pressure Switch Manifold (PSM) Logic Pressure Switch Manifold (PSM) Logic Page 23927 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Specifications Connecting Rod: Specifications Connecting Rod Nut First Pass ............................................................................................................................................. ..................................................... 27 N.m 20 lb ft Final Pass ............................................................. ........................................................................................................................................... 70 degrees Connecting Rod Side Clearance ............................................................................................................................................ 0.15-0.44 mm 0.006-0.017 in Page 2208 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 5144 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 12735 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 18233 Service and Repair Grille: Service and Repair Radiator Grille Replacement (Chevrolet) Page 7648 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 963 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Locations High Beam Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 23882 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 9998 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 2428 Page 16189 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 3707 3. Install the discharge hose to the condenser using new sealing washers. Notice: Refer to Fastener Notice. 4. Install the discharge hose nut to the condenser. Tighten the nut to 16 N.m (12 lb ft). 5. Install the upper air baffle. 6. Install the discharge hose (1) to the A/C compressor using new sealing washers. 7. Install the discharge hose mounting bolt. Tighten the bolt to 16 N.m (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Page 23620 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 939 Page 24188 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 6604 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. OnStar(R) - False Crash Detection Customer Calling Emergency Contact Module: All Technical Service Bulletins OnStar(R) - False Crash Detection Customer Calling TECHNICAL Bulletin No.: 08-08-46-002 Date: June 26, 2008 Subject: OnStar(R) Calls Unwanted, False Crash Detection Customer Calling (Reprogram SDM) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with OnStar(R) (RPO UE1) Condition Some customers may comment on receiving unwanted calls from the OnStar(R) Center. Cause During certain extreme vehicle maneuvers, the vehicle SDM may mistakenly detect a crash event and generate a call to the OnStar(R) call Center. The OnStar(R) advisor is connected to the vehicle to see if everyone is alright and if a request for emergency help is needed. Correction A revised SDM Operating System software has been developed to address this issue. Reprogram the Sensing and Diagnostic Module (SDM) with the controller option described as "SDM Sensing and Diagnostic Module" under Operating System using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 2073 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 14951 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 14900 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 7630 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 6401 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure Page 9788 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Diagrams Clearance Lamp: Diagrams Lighting Systems Connector End Views Clearance Lamp - Left Front (RO5) Clearance Lamp - Left Rear (RO5) Clearance Lamp - Right Front (RO5) Page 12994 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 15218 Page 20698 Door Latch Assembly - Left Rear (Crew Cab) Page 7317 Page 24190 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 20053 Radio Front Speaker Grille Replacement Radio Front Speaker Grille Replacement Page 6651 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 10176 Page 6720 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 10786 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 5400 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Remove the knock sensor heat shield bolt and shield. Page 17358 X207 Inline Harness Connector End Views X207 I/P Harness to I/P Harness (6J4) Page 5714 Body Control Module (BCM) X5 Page 10394 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 21121 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (Cheyenne LT LS) Endgate Emblem/Nameplate Replacement (Cheyenne LT LS) Page 22592 Driver Door Switch (DDS) X7 (AN3/DL3) Page 2761 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 17334 Page 14207 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) Tools Required * J 8092 Universal Driver Handle-3/4 in - 10 * J 21128 Axle Pinion Oil Seal Installer * J 23690 Axle Shaft Bearing Installer * J 2619-01 Slide Hammer * J 44685 Rear Axle Seal and Bearing Remover Removal Procedure 1. Remove the axle shaft. 2. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (1) and the J 2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Locations Power Door Lock Switch: Locations Vehicle Access Component Views Driver Door 1 - Door Frame 2 - Window Switch - Driver (A31 -AN3/DL3) 3 - Outside Rearview Mirror - Driver 4 Memory/Heated Seat Switch (AN3) 5 - Outside Rearview Mirror Switch (DL8/DPN) 6 - Driver Door Switch (DDS) (AN3/DL3) 7 - Speaker - Left Front 8 - Window Motor - Driver (A31) 9 - Door Lock Switch - Driver (AU3 -AN3/DL3) 10 - Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) 11 - Door Latch Assembly - Driver Passenger Door Page 2979 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 16148 Fuse Block: Locations Entertainment/Communication Component Views Entertainment/Communication Component Views Behind the I/P 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 +YE9) 6 - Digital Radio Receiver (U2K) Page 7947 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 14266 Installation Procedure Important: Carefully insert the axle shaft in order to not damage the seal. 1. Install the axle shaft (1) into the rear axle housing (5). 2. Slide the axle shaft (1) into place allowing the splines to engage the differential side gear. 3. On axles without a locking differential, place the lock (4) on the button end of the axle shaft (1). 4. On axles with a locking differential, keep the pinion shaft partially withdrawn. 5. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2). 6. Pull the shaft flange outward in order to seat the lock in the differential gear. Page 22281 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 16456 Page 1904 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 9770 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 14142 2. For the 11.5 inch axle, install the differential side bearings by doing the following: 1. In order to protect the differential case, install the J 8107-5 in the case on the side opposite the bearing installation. 2. Install the J 44420 (2) and the J 8092 (1) onto the differential case bearing as shown. 3. Drive the bearing onto the case using the J 44420 and the J 8092. 3. Install the differential assembly. Page 15755 5. Remove the generator battery jumper cable to fuse nut (3). 6. Remove the generator battery jumper cable terminal (4) from the fuse stud. 7. Remove the positive battery cable terminal from the fuse stud. 8. Remove the fuse from the holder. Installation Procedure Page 13800 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 1165 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 8567 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 9658 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 9141 Procedures Fluid - Differential: Procedures Rear Axle Lubricant Level Inspection (8.6 Inch Axle) Rear Axle Lubricant Level Inspection (8.6 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Fabricate a dipstick from a pipe cleaner or similar item. Form the pipe cleaner into an "L". 7. Insert the pipe cleaner into the fill plug opening with the stem facing down. 8. Remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant level. The distance between the bend and the lubricant level should be 15-40 mm (0.6-1.6 in). 9. If the measurement is greater than 40 mm (1.6 in), add lubricant until the level is between 15-40 mm (0.6-1.6 in) from the bottom edge of the fill plug hole. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Notice: Refer to Fastener Notice. 10. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 11. Lower the vehicle. Rear Axle Lubricant Level Inspection (11.5 Inch Axle) Rear Axle Lubricant Level Inspection (11.5 Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. Page 23887 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 13182 Disclaimer 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 16006 Fuse: Locations Right I/P Junction Block Junction Block - Right I/P, Top View Page 13573 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 13024 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 1798 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 11313 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 21040 6. Disconnect the rear sliding window electrical connectors from the motor/module and relays (1). 7. Remove the rear sliding window motor/module assembly from the vehicle. Installation Procedure 1. Install the rear sliding window motor/module assembly to the vehicle. 2. Connect the rear sliding window electrical connectors to the motor/module and relays (1). Notice: Refer to Fastener Notice. 3. Install the rear sliding window motor/module nuts (2). Tighten nut to 10 N.m (89 lb in). 4. Install the rear sliding window regulator and cables (2) to the motor/module. 5. Install the bolt (1) to the rear sliding window regulator and cables (2). Page 7846 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 9724 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 17174 Fuse Block - Underhood X5 Page 21159 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 14158 2. For the 9.5/9.5LD and the 10.5 inch axles, remove the rear axle fill plug. 3. For the 11.5 inch axle, remove the fill plug. 4. Remove the rear axle drain plug. 5. Drain the lubricant into a suitable container. 6. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 7. Clean the drain plug. Installation Procedure Notice: Refer to Fastener Notice. 1. Install the rear axle drain plug. Tighten the rear axle drain plug to 33 N.m (24 lb ft). 2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. Page 425 Page 23926 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 9358 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 20428 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Navigation Radio - Various Malfunctions Navigation System: All Technical Service Bulletins Navigation Radio - Various Malfunctions TECHNICAL Bulletin No.: 08-08-44-002B Date: April 14, 2009 Subject: Navigation Radio Clock and/or Clock Tab Do Not Appear or Disappears Intermittently, Split Screen, Points of Interest or Exit List Appears While Driving, Text Color May Be Difficult to See, Address Book Characters May Be Hard to Find, Cannot Scroll Through XM Radio Categories, I Agree Screen Lockouts (Update Navigation Radio with New Software) Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008 HUMMER H2 with Navigation Radio RPO UVB or U3U Supercede: This bulletin is being revised to add additional customer concerns and to update the list of Operating Characteristics the software addresses. Please discard Corporate Bulletin Number 08-08-44-002A (Section 08 - Body & Accessories). Condition Some customers may comment about any of the following conditions: - The clock and/or clock tab does not appear or disappears intermittently on the navigation screen. - A split screen, points of interest or an exit list may appear on the navigation screen while driving. - The text color may be difficult to see on light color backgrounds. - The address book entry characters may be hard to find. - The customer may not have the ability to scroll through the XM radio categories while the vehicle is in motion. - The customer may not be able to scroll through music navigator, MP3 folders, address book, POI's and Turn List when the vehicle is in motion. - "I Agree" screen appears every ignition cycle. - Destination entry screens do not have a "back" button to return to previous page. - Customer is not able to adjust screen brightness while vehicle is in motion. Cause These conditions may be caused by a software anomaly. Correction Using the Tech 2(R), verify that the vehicle is equipped with one of the following radio part numbers: Important If the vehicle is not equipped with one of the following radio part numbers, disregard this bulletin. - 15882766 Page 3391 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: * The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. * Apply the park brake. * The engine must start in the park (P) or neutral (N) positions only. * Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 23451 Disclaimer Page 4884 Page 14587 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 18227 Air Register: Service and Repair Side Window Air Outlet Replacement Side Window Air Outlet Replacement Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Page 3592 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 177 Vehicle Zoning Strategy Truck Zoning Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 11547 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 2548 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Page 21570 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Service and Repair Ignition Coil: Service and Repair Ignition Coil Replacement Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Disconnect the chassis fuel feed pipe (1) quick connect fitting from the engine fuel feed pipe. 3. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor. 4. Disconnect the engine wiring harness electrical connector (1) from the evaporative emission (EVAP) canister purge solenoid valve. Page 24730 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 11839 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8528 Page 6073 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 19830 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 14668 10. Using J 28458, release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. 12. Inspect the TCC solenoid and wiring harness for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Page 3066 Page 2644 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 4156 Page 1806 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Rear Side Door Inside Handle Replacement (with SLT) Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement (with SLT) Rear Side Door Inside Handle Replacement (with SLT) Page 5033 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 3004 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 5294 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Audio System - Static/Ignition Noise on AM Band Ground Strap: Customer Interest Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Page 1095 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 19149 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement A/T - Fluid Pan Magnet Upgrade Fluid Pan: Technical Service Bulletins A/T - Fluid Pan Magnet Upgrade INFORMATION Bulletin No.: 08-07-30-040B Date: May 05, 2009 Subject: Information on Normal Maintenance or Warranty Service for 4T40, 4T45, 4T65, 4L60 Automatic Transmission Oil Pan Magnet Upgrade Models: 2002-2009 GM Passenger Cars and Light Duty Trucks Equipped With the Following Transmissions: 4T40-E or 4T45 HYDRA-MATIC(R) Automatic Transmission (RPOs MN4, MN5, ME7) 4T65 Transmission (RPO M15 and MN7) 4L60 Transmission and Derivatives (RPO M30 is 4L60, M32 is 4L65, M70 is 4L70) Attention: Do not remove the transmission oil pan unless normal maintenance or diagnosis of a customer concern requires it. .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add 4T65 and 4L60 transmissions. Please discard Corporate Bulletin Number 08-07-30-040A (Section 07 - Transmission/Transaxle). .............................................................................................................................................................. .................................................................................. A new transmission oil pan magnet, P/N 29535617, was released for service. The current square transmission oil pan magnet may become saturated with normal ferrous sediment and the Pressure Control Solenoid (PCS) is now collecting ferrous sediment, making it vary from design. For a given current the PCS electromagnet is stronger, causing the line pressure to be less than needed. When checking PCS line pressure (refer to Line Pressure Check in SI) and it shows that the line pressure is lower than required (refer to Current-Amps/Line Pressure Chart in SI), for a given current at the PCS or the transmission oil pan was removed (for either normal maintenance or warranty service), only then should the transmission oil pan magnet be upgraded. 1. Remove and discard the original square transmission oil pan magnet and install a new one in the current location (See graphics below for the correct application). 2. Install the second new transmission oil pan magnet in the following location as shown in the illustration. 4T40 & 4T45 4T65E Page 5354 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 16269 Junction Block - Left I/P X1 (Pin A1 To M1) Page 554 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Locations Manifold Pressure/Vacuum Sensor: Locations Engine Controls Component Views Rear of the Engine 1 - Central Sequential Fuel Injection (SFI) Module 2 - Manifold Absolute Pressure (MAP) Sensor 3 G106 4 - Engine Oil Pressure (EOP) Sensor 5 - Ignition Control Module (ICM) 6 - G107 Page 23116 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 10424 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 14984 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 5787 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21343 The outline portion (1) of the insulator should Only be removed if the vehicle is equipped with the manual 4x4 shifter. All other vehicles should use the complete piece. Remove the two protective paper strips (1) from the insulator. Attach the glue side of the insulator to the top of the floor tunnel as shown in the above illustration. Reposition the carpet or rubber floor covering back down into position. Install the body lock pillar trim panels. Refer to Body Lock Pillar Trim Replacement in SI. Install the jack and the jack handle kit. Refer to Jack Stowage Cover Replacement in SI. Install the IP support bracket, bolts and trim covers. Tighten Page 22260 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Page 7050 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 2842 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 12506 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. 6. Enable the SIR system. Page 18181 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Page 16741 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11280 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 8494 Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (2) up and over the knock sensor. Page 9530 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 1166 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 17023 Fuse Block: Locations HVAC - Manual HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 2953 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 15628 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 9042 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20522 Body Control Module (BCM) X6 Page 2539 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 6509 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 14777 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 5108 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 8253 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 22345 Page 5791 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9031 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 12859 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 15347 Rear Brake Caliper Bracket Replacement (JD9) Rear Brake Caliper Bracket Replacement (JD9) Page 20699 Door Latch Assembly - Passenger Door Latch Assembly - Right Rear (Crew Cab) Page 1481 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 19455 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 3404 Transmission Speed Sensor: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 11269 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Locations Shift Interlock Solenoid: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 17289 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (4.3L/4.8L/5.3L) Page 13685 Important: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. 3. Install the range selector cable to the support. 4. Ensure that the transmission manual shaft lever is in the mechanical park position. 5. Install the cable to the steering column bracket. 6. Ensure the tangs fully seat (snap) into the steering column bracket. 7. Install the cable end to the steering column ball stud. Page 3490 Alignment: Service and Repair Wheel Alignment Procedures Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: * Inspect the tires for the proper inflation and irregular tire wear. * Inspect the runout of the wheels and the tires. * Inspect the wheel bearings for backlash and excessive play. * Inspect the ball joints and tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. * Inspect the vehicle trim height. * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. Front Caster and Camber Adjustment Front Caster and Camber Adjustment Important: Caster measurements are now relative to ground. 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper 3 times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection. 2. For an accurate reading, do not push or pull on the tires during the alignment process. Page 23574 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 6714 Page 9093 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Service and Repair Door Lock Cylinder: Service and Repair Door Lock Cylinder Replacement Page 7009 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 623 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 6780 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 12843 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 3067 Page 19616 Memory Seat Module X6 (AN3) Page 7581 View of the connector when released from the component. View of another type of Micro 64 connector. Page 8585 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 8401 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 17157 Junction Block - Right I/P (Wire Entry) (Pin 4B7 To 6B) Junction Block - Right I/P X2 Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 4525 12. Install the PCV hose. 13. Tighten the air cleaner outlet duct clamp at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). Page 18781 Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Crew Cab +ASF) Page 6638 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 14935 Page 21507 Page 7028 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 7196 Page 13586 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 19375 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Tail/Stop and Turn Signal Lamp - Lower Right 4 - Marker Lamp - Right Rear 5 - Backup Lamp Right Rear 6 - Object Sensor - Right Rear Corner (UD7) 7 - License Lamp - Right 8 - Object Sensor - Right Rear Middle (UD7) 9 - Marker Lamp - Tailgate (R05) 10 - Object Sensor - Left Rear Middle (UD7) 11 - License Lamp - Left 12 - Object Sensor - Left Rear Corner (UD7) 13 - Backup Lamp - Left Rear 14 - Marker Lamp - Left Rear 15 - Tail/Stop and Turn Signal Lamp - Lower Left Page 20524 Auxiliary Body Control Module (XBCM) X1 (Export) Page 22215 Rear Seat Back Cushion Frame Replacement (Extended Cab with AM7) Rear Seat Back Cushion Frame Replacement (Extended Cab with AM7) Page 6937 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 9515 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9839 Throttle Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 11275 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 5171 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 18286 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 1632 Low Pressure Sensor / Switch: Diagrams HVAC - Manual HVAC Connector End Views A/C Low Pressure Switch (C67) Reverse Lockout Solenoid Page 10507 6. This step applies to the Push Down TI style connector ONLY. Release the fitting by pressing on the tab indicated by the arrow. Caution: Refer to Relieving Fuel Pressure Caution. 7. Pull the connection apart. Connect Procedure Caution: Refer to Fuel Pipe Fitting Caution. 1. Apply a few drops of clean engine oil to the male connection end. 2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place. Page 13435 21. Remove the spacer plate support bolts (77). 22. Remove the spacer plate support (53). 23. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). Notice: Refer to Fastener Notice. 2. Install the spacer plate support (53) and bolts (77). Tighten the bolts to 10 N.m (89 lb in). Page 5623 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 2692 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 5471 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 11977 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 12336 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 2964 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 15328 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed Procedure (Without JL4) Antilock Brake System Automated Bleed Procedure (With JL4). 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes Page 12590 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 12173 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. Tighten the bolts to 12 N.m (108 lb in). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Page 6353 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 11927 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 2987 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 7558 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 22344 Rear Seat Cushion Frame Replacement (Extended Cab with A68) Rear Seat Cushion Frame Replacement (Extended Cab with A68) Page 12594 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 14713 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 24225 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 21791 Page 15280 Caution: Refer to Brake Dust Caution. 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7) Front Disc Brake Pads Replacement (JH6, JH7) and/or Rear Disc Brake Pads Replacement (JD9) Rear Disc Brake Pads Replacement (JH6, JH7). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Inspect the friction surfaces of the brake rotor for the following Braking Surface Conditions: * Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the rotor. * Cracks and/or heat spots * Excessive blueing discoloration 4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions, the rotor requires refinishing or replacement. 5. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the scoring depth of any grooves present on the rotor friction surfaces. 6. Compare the groove scoring depth recorded to the following specification: Brake rotor maximum allowable scoring: 1.50 mm (0.059 in) 7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present, the rotor requires refinishing or replacement. Brake Rotor Thickness Measurement Brake Rotor Thickness Measurement Caution: Refer to Brake Dust Caution. 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7) Front Disc Brake Pads Replacement (JH6, JH7) and/or Rear Disc Brake Pads Replacement (JD9) Rear Disc Brake Pads Replacement (JH6, JH7). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the thickness of the brake rotor at four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in) for each measurement. Specifications Luggage Rack: Specifications Fastener Tightening Specifications Page 10076 6. Disconnect the EVAP vent solenoid pipe quick connect fitting (3) from the EVAP canister. 7. Remove the EVAP vent solenoid pipe clip (1) from the frame crossmember. 8. Insert a small flat bladed tool between the EVAP canister vent solenoid and the fuel tank bracket, disengaging the retainer (1). 9. Slide the EVAP canister vent solenoid off the bracket towards the passenger side of the vehicle. 10. Remove the EVAP canister vent solenoid from the vehicle. Installation Procedure Page 6809 Page 11227 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 9230 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Campaign - Front And Rear Chrome Interior Door Handle Technical Service Bulletin # 09239A Date: 100825 Campaign - Front And Rear Chrome Interior Door Handle SPECIAL COVERAGE Bulletin No.: 09239A Date: August 25, 2010 Subject: 09239A - Special Coverage Adjustment - Front and Rear Chrome Interior Door Handle Lever Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL Equipped with Chrome Interior Door Handles Supercede: The Parts Information section has been revised to include a note that P/N 88880051 is used for the front and rear doors. Step 6 under the Rear Side Door Inside Handle Replacement procedure has also been revised to refer technicians to the Rear Side Door Inside Handle Replacement in SI.Please discard all copies of bulletin 09293, issued July 2010. Condition Some customers of 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles may comment about peeling on the top surface of the front or rear chrome interior door handle(s). A chrome plating irregularity combined with direct sunlight exposure may cause the plating to separate from the top surface of the handle on certain vehicles. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership or mileage. Dealers are to replace the front and/or rear chrome interior door handle levers if signs of peeling are present. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after July 16, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to July 16, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles built within the following VIN breakpoints: Page 16300 Page 6277 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 7508 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 14254 Note: Ensure the seal is fully seated in the hub bore. 13. Using the J 44420 installer (2) and the J 8092 handle (1), install the new oil seal. 14. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Note: If the rear axle hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the rear axle hub seal must be replaced. 15. Install the rear axle hub. Page 13196 Notice: Refer to Fastener Notice. 5. Install the oil pan bolts. Tighten the bolts alternately and evenly to 11 N.m (97 lb in). 6. Install the catalytic converter. 7. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 N.m (18 lb ft). 8. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 23475 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 9076 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 10992 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 21424 Drink Holders: Service and Repair Front Floor Console Cup Holder Replacement Page 23938 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 1847 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 12849 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 5450 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 3950 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 23009 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 11705 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 10950 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 12924 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 7578 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 12247 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 13009 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 6520 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 22132 Memory Seat Module X7 (AN3) Page 15878 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 3068 Page 13228 Fluid Line/Hose: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Removal Procedure Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: * Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. * Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. * Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Install a new retaining ring into the quick connect fitting using the following procedure: Page 12289 Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 2814 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 23235 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 2895 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 13814 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 23071 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 6298 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 621 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 1880 Air Flow Meter/Sensor: Connector Views Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 6465 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 23859 Marker Lamp: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 24441 7. Install the rear sliding window pulley covers (2) to the pulley (3), clip the tabs (1) in place. 8. Install the rear sliding window stops (1) in place and fully seated. 9. Cycle the rear sliding window to the fully closed position. 10. Install the lower garnish molding. 11. Inspect the rear sliding window for proper operation. 12. Clean the window. Page 990 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 6687 Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice Excessive Force and Oxygen Sensor Notice Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Engine Mount Replacement - Left Engine Mount: Service and Repair Engine Mount Replacement - Left Engine Mount Replacement - Left Side Removal Procedure Notice: Refer to Engine Mounting Notice. 1. From under the hood, remove the engine mount to engine mount bracket bolts. (right side shown, left side similar). 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the oil pan skid plate bolts and plate. Notice: Refer to Engine Lifting Notice. 4. Using an adjustable jack on the square tab at the rear of the engine block, raise the engine. Page 11306 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 5200 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 7077 Page 11162 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Locations Battery Current Sensor: Locations Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor Page 16757 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 13013 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 17095 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 12854 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 7319 Page 17494 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Diagram Information and Instructions Fuse: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 21808 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 18110 Disclaimer Page 10199 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 22949 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 10375 Page 12470 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Diagrams Headlamp Switch: Diagrams Lighting Systems Connector End Views Headlamp and Panel Dimmer Switch Page 12740 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 14321 Page 1506 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Page 5579 2. Install the spark plug wires. Locations Washer Fluid Level Switch: Locations Wiper/Washer Component Views Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Washer Fluid Level Switch 7 Windshield Washer Fluid Pump 8 - Air Cleaner Box Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Removal Procedure 1. Beginning at the joint located in the center rear of the lace of the sunroof opening, pull the sunroof finishing lace from the sunroof window track assembly. 2. Remove the sunroof finishing lace from the track. Installation Procedure 1. Position the end of the sunroof finishing lace at the center rear of the sunroof opening. Page 3744 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Page 3694 2. Lubricate the O-ring seal with clean engine coolant. 3. Install the water outlet. Notice: Refer to Fastener Notice. 4. Install the water outlet bolts. Tighten the bolts to 21 N.m (15 lb ft). 5. Install the radiator inlet hose. 6. Install the air cleaner outlet resonator duct. Page 13888 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 7987 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 21178 OnStar(R) - Language Change Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Page 16158 Page 22657 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Page 7532 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Notice: Refer to Fastener Notice. 2. Install the accelerator pedal bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: Page 16101 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 23000 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 1797 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 3037 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 14325 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14930 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 11184 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 19089 17. Separate the 2 banana plugs on the SIR deployment harness. 18. Place a 12 volt minimum/2 amp minimum power source, such as a vehicle battery, near the shorted end of the harness. 19. Connect the SIR deployment harness wires to the power source. Seat belt pretensioner deployment will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source after the seat belt pretensioner deploys. 21. Seat one banana plug into the other in order to short the deployment harness leads. 22. If the seat pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the seat belt pretensioner as soon as possible. 25. Dispose of the deployed seat belt pretensioner through normal refuse channels. 26. Wash hands with a mild soap. Deployment Inside Vehicle - Vehicle Scrapping Procedure Deploy the seat belt pretensioners inside of the vehicle when destroying the vehicle or when salvaging the vehicle for parts. This includes but is not limited to the following situations: * The vehicle has completed its useful life. * Irreparable damage occurs to the vehicle in a non-deployment type accident. * Irreparable damage occurs to the vehicle during a theft. * The vehicle is being salvaged for parts to be used on a vehicle with a different VIN as opposed to rebuilding as the same VIN. Page 14850 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 2007 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Controls Connector End Views Engine Coolant Temperature (ECT) Sensor Page 20310 Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Page 6611 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 9371 Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face the engine front cover. Failure to do so will damage the front cover and the reluctor ring. 1. Install the CKP sensor reluctor ring. 1. Align the keyway on the CKP sensor reluctor ring with the key in the crankshaft. 2. Using J 5590, push the CKP sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. 2. Install the engine front cover. Page 21969 2. Insert the end of the sunshade (1) to the driver side bracket (2) notch. 3. Insert the sunshade (1) to the passengers side bracket (2) notch. Page 24090 Important: Use a NEW steering shaft lock plate retaining ring. 1. Install the following parts onto the steering shaft: 1. Lubricate the turn signal switch cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam position plate (2) 3. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137. 2. Install the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Page 15927 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 14789 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 22360 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 9320 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 16950 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 19097 Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) Page 10177 Locations Oxygen Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 5084 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 11827 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 6578 Page 8615 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 9176 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 12700 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 5844 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 201 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 6954 Page 15273 6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the J 39544-KIT, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation. 8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14. 9. If the brake rotor meets the following criteria, proceed to step 10. * The rotor is within specifications and is being REUSED * The rotor has NOT been refinished * The rotor does NOT exhibit thickness variation exceeding the maximum allowable level 10. Mount a dial indicator, J 45101, or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 11. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 12. Compare the brake rotor assembled LRO to the following specifications: Brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in) Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.25 mm (0.010 in) 13. If the brake rotor assembled LRO is within specifications, proceed to step 18. Page 14625 Transmission Speed Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 504 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 23619 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 1578 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Page 4048 View of the connector when released from the component. View of another type of Micro 64 connector. Page 7045 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 16221 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 11389 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 12612 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Air Bag System - DTC B0071/B0074/B0081 Code Clearing Seat Occupant Sensor: All Technical Service Bulletins Air Bag System - DTC B0071/B0074/B0081 Code Clearing Bulletin No.: 07-09-41-004 Date: June 13, 2007 INFORMATION Subject: New Procedure for Clearing Passenger Presence System (PPS) and Sensing and Diagnostic Module (SDM) DTCs B0071, B0074, B0081 Models: 2006-2008 Buick Lucerne 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Monte Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Silverado, Suburban, Tahoe 2007-2008 GMC Yukon, Yukon Denali, Yukon XL, Yukon XL Denali A condition exists where the passenger presence system (PPS) may continue to output a fault to the sensing and diagnostic module (SDM) after the PPS has been cleared. The fault may continue to report to the SDM if the buss has not been allowed to go to sleep prior to clearing B0081 DTC in the SDM. If B0071, B0074 or B0081/0F is received, the following procedure should be followed to clear the codes. With the Ignition OFF, open and close the driver door. With a scan tool, clear PPS DTC (B0071 or B0074). While continuing to keep the doors closed, wait 60 seconds with the ignition OFF. DO NOT operate any functions in the vehicle during this time. Verify that the PPS does not have any DTCs. If PPS DTCs exist, please perform the necessary repair. With the scan tool, clear DTC B0081. Disclaimer Page 12152 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 8122 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Page 6938 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 24434 Page 21558 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 8217 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 175 Page 18202 Recirculation Actuator (C67) Page 1109 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 3145 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 8941 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 4275 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 10744 Page 12943 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 4969 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 17322 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness Page 6087 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 23614 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 11901 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 5468 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 11298 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Campaign - BCM Reprogramming for Battery Drain Body Control Module: Recalls Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 3051 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 9161 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2845 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 1125 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 15148 Page 6259 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Controls Connector End Views Engine Coolant Temperature (ECT) Sensor Brakes - Aftermarket Trailer Brake Controllers Trailer Brake Control Module: All Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 4414 Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 6. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 7. Replace the fuse(s) in the fuse panel when finished towing. Tracker Models Note: Locking the steering column when towing your vehicle may damage the steering column. Always unlock the steering column before towing. Important: ^ Two-wheel drive Trackers cannot be dinghy towed. Two-wheel drive models MUST be towed with the rear drive wheels on a dolly. ^ The towing speed must not exceed 90 km/h (55 mph). In order to properly dinghy tow a 4WD Tracker, follow these steps: 1. Set the parking brake. 2. Shift the transmission into Park (AT) or second gear (MT). 3. With the ignition key in the ON position, move the transfer case to Neutral. Make sure the 4WD indicator on the instrument panel cluster is Off. 4. Turn the ignition key to ACC in order to unlock the steering wheel. 5. Release the parking brake. Stop towing the vehicle every 300 km (200 mi) and do the following steps: 1. Start the engine of the towed vehicle. 2. Leave the transfer case shift lever in Neutral. 3. Shift the transmission to Drive (AT). For vehicles with (MT), leave the transmission in second gear with the clutch engaged. 4. Run the engine at medium speed for one minute to circulate the oil through the transfer case. 2003-2007 Pontiac Vibe Only the front wheel drive vehicles with manual transmission are designed to be dinghy towed. Use the following procedure to properly dinghy tow these models: 1. Place the shift lever in Neutral. 2. Turn the ignition switch to the ACC position to avoid locking the steering wheel. Make sure that the audio system is turned off and that nothing is plugged into the power outlets. 3. Release the parking brake. 4. After dinghy towing the vehicle, let the engine idle for more than three minutes before driving the vehicle. Four Wheel Drive and All Wheel Drive Light Duty Trucks Page 23630 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 11180 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 7948 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Diagrams Memory Positioning Module: Diagrams Power Seat Connector End Views Memory Seat Module X1 (AN3) Memory Seat Module X2 (AN3) Locations Dimmer Switch: Locations Lighting Systems Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 15207 Front Brake Caliper Replacement (JH6, JH7) Front Brake Caliper Replacement (JH6, JH7) Body - Tonneau Cover Fits To Loose On Vehicle Truck Bed Cover Latch: Customer Interest Body - Tonneau Cover Fits To Loose On Vehicle TECHNICAL Bulletin No.: 09-08-66-003A Date: December 23, 2010 Subject: One-Piece Hard Tonneau Cover Fits Loose on Vehicle or Rear Tonneau Latch Not Functioning Properly (Adjust Rear Latch and Align Tonneau Cover) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-003 (Section 08 - Body and Accessories). Condition Some customers may comment that the hard tonneau rear latch is not functioning properly or that the tonneau cover is loose on the vehicle, causing noticeable movement during vehicle operation. Cause This condition may be caused by both sides of the latch not engaging or releasing at the same time, or the tonneau frame may be misaligned. Correction Note The tonneau cover latches contain multiple design features to accommodate for build variation of the pickup box and tonneau cover. Use the following repair process to obtain proper latch operation: Inspect/Adjust Latch to Striker Loop Interface Side to Side Adjustment 1. Lower the endgate. 2. Slowly lower the tonneau cover from the open to closed position. Use caution not to drop or slam the tonneau cover closed as this may damage the latch assembly. 3. Inspect the fit of the latch into the striker loop just before the U-shaped catch is engaged. The latch should fit into the striker loop without contacting any portion of the rear bracket or striker loop. If contact is observed, proceed with the following steps: 1. Loosen the two nuts of the rotary latch that is making contact to the striker loop assembly with a 7/16 inch wrench. 2. Slide the rotary latch side to side until the latch freely falls into the rear striker loop. 3. Tighten the rotary latch nuts to 2.26 Nm (20 lb in). 4. Inspect the operation of the latches by turning the twist handle. If the latches do not close or release properly, adjust the latch wire per the Inspect/Adjust Latch Release Operation section of this document. Up and Down Adjustment 1. Lower the endgate. 2. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 3. Inspect the fit of the tonneau cover side seal to the pickup box. If the seal does not have complete contact, lower the striker loop until the seal has complete contact using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Lower the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). 4. Inspect for seal contact and repeat procedure as necessary. 4. Close the endgate. 5. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 6. Inspect that both latches have engaged by lifting up on the corner of the tonneau. Page 16917 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 1328 Parking Assist Distance Sensor: Locations Object Detection Component Views Rear of the Vehicle (X88) 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Backup Lamp - Right Rear 4 - Tail/Stop and Turn Signal Lamp - Lower Right 5 - Object Sensor Right Rear Corner (UD7) 6 - License Lamp - Right 7 - Object Sensor - Right Rear Middle (UD7) 8 Marker Lamp - Tailgate (R05) 9 - Object Sensor - Left Rear Middle (UD7) 10 - License Lamp - Left 11 - Object Sensor - Left Rear Corner (UD7) 12 - Tail/Stop and Turn Signal Lamp - Lower Left 13 Backup Lamp - Left Rear Rear of the Vehicle (Z88) Page 6656 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 24649 Page 24273 1 - Window Switch - Right Rear (ABV) 2 - Window Motor - Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 4 - Speaker - Right Rear Door Page 4962 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 1029 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 4925 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 17779 1 - X201 2 - X276 (KA9) 3 - Heated Steering Fuse (KA9) 4 - X277 (KA9) 5 - X275 Page 5802 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 20538 Auxiliary Step / Running Board: Service and Repair Assist Step Replacement Page 6990 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 13797 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 13438 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten the bolts in the sequence shown to 11 N.m (97 lb in). 15. Ensure that the manual detent spring is aligned properly with the detent lever. Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 5840 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 16570 Not all of the effects or driver notifications listed above have been experienced. However, the different effects and driver notifications may be caused by one of the wires in the IP harness being chafed or cut. Components on different lines in the list above are in different circuits. Due to the cause of the condition, and the positions of the wires in the IP harness, it is unlikely that more than one circuit will be affected by the condition. Upon investigation, the technician may find several DTCs set as current or in history. The technician may also find one or more blown fuses in the IP and underhood fuse blocks. The potential fuses are listed below: 60 amp MBEC1 (# 72) (Underhood) 30 amp AMP (# 40) (Underhood) 15 amp RDO (# 41) (Underhood) 10 amp IPC (# 46) (Underhood) 15 amp AIRBAG BATT (# 51) (Underhood) 10 amp DSM (Left side of IP) Cause The condition may be caused by one of the wires in the IP harness being chafed or cut on the parking brake pedal assembly. Five areas of potential contact have been identified and are shown. Page 17992 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. 3. Dismount the tire from the rim. Important: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 3001 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 9886 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 22116 Memory Seat Module X5 (AN3) Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Temperature Versus Resistance Page 2373 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: Customer Interest A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Page 5767 Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: Customer Interest Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8319 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 6763 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 6278 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 14753 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Locations Horn Relay: Locations Horn Relay The Horn PCB Relay is located in the Fuse Block - Underhood. Note: This relay is a Printed Circuit Board (PCB) Relay, and is not serviceable. Page 23432 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 8334 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 2252 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 18778 Impact Sensor: Diagrams SIR Connector End Views Inflatable Restraint Front Sensor - Left (10 Series) Inflatable Restraint Front Sensor - Right (10 Series) Inflatable Restraint Front Sensor (-10 Series) Page 15278 Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these conditions, perform the following steps: 1. Remove the brake rotor from the vehicle. 2. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 3. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface of the brake rotor. 4. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Install the rotor to the hub/axle flange using the matchmark made prior to removal. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1), and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the J 39544-KIT, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation. 8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14. 9. If the brake rotor meets the following criteria, proceed to step 10. * The rotor is within specifications and is being REUSED * The rotor has NOT been refinished * The rotor does NOT exhibit thickness variation exceeding the maximum allowable level Page 5318 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2549 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 16987 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 249 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 21584 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 9070 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 8268 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 15480 8. Disconnect the park brake cable eye (3) from the park brake actuator lever (2). 9. Remove the park brake cable from the bracket by pulling the cable conduit (1) rearward to compress the spring and sliding the cable conduit out of the bracket. 10. Remove the park brake cable assembly from the vehicle. Installation Procedure 1. Connect the right park brake cable eye (3) to the park brake actuator lever (2). 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward to compress the spring and inserting the cable conduit into the rear axle bracket. Page 1179 Ignition Control Module: Diagrams Engine Controls Connector End Views Ignition Control Module (ICM) Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: Customer Interest Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 19384 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Page 176 Page 10562 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 15667 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice. 2. Install the park brake warning lamp switch bolt. Tighten the bolt to 3 N.m (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. 5. Connect the negative battery cable. Page 4364 5. Clean and mask and paint the wheels. General Refinishing Procedures - Installation 1. Unmask the wheels. 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. Important: When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 3. Install NEW coated balance weights at marked locations. Important: Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed. 4. Install wheels on vehicle. Repair Option Number 2 - Outside Companies * Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist. * Any process that re-machines or otherwise remanufactures the wheel should not be used. * The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. * Paint and/or clearcoat must not be present on the following surfaces, the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. * A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Page 8357 Low Speed Bus - 3 of 3 Page 6810 Page 11772 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 17307 X211 Inline Harness Connector End Views X211 Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) to Console Harness (Y91/UQA/D07) Page 2430 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Page 2954 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 24720 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 15488 Parking Brake Lever: Service and Repair Parking Brake Lever Pedal Assembly Replacement Parking Brake Lever Pedal Assembly Replacement Removal Procedure Important: The following service procedure includes the removal of the front park brake cable. The front park brake cable is NOT serviced separately, but serviced with the park brake pedal assembly. 1. Remove the left side hinge pillar trim panel. 2. Disconnect the park brake warning lamp electrical connector. 3. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling. 4. Remove the bolt and disconnect the park brake pedal release handle from the instrument panel. 5. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side. 6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 7. Disconnect the front park brake cable from the intermediate cable connector by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector. 8. Release the front park brake cable from the frame by depressing the locking tabs. 9. Lower the vehicle. Page 13526 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 11994 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Reposition the knock sensor sleeve (3) down, away from the knock sensor. 4. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 15089 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Page 10484 Fuel Injector 6 Page 8877 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Page 1862 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 5087 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 2718 Page 13584 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 16444 X110 Inline Harness Connector End Views X110 Engine Harness (-Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF/NQG/NQH/NP2) Page 8909 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 16114 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If vehicle is a 2-wheel drive (2WD) perform the following steps, otherwise proceed to step 5. 3. Disconnect the connector position assurance (CPA) retainer. 4. Disconnect the HO2S pigtail electrical connector (7) from the engine wiring harness electrical connector (6). 5. If vehicle is a 4-wheel drive (4WD) perform the following steps, disconnect the CPA retainer. 6. Disconnect the engine wiring harness electrical connector (7) from the HO2S pigtail electrical connector (8). Locations Wheel Speed Sensor: Locations Antilock Brake System Component Views Front Sensors 1 - Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7/JH6/JH7) 2 - Chassis 3 - Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7/JH6/JH7) Rear Sensors Page 6019 * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Page 9572 Vehicle Zoning Strategy Truck Zoning Page 20203 Entertainment System Control Module: Diagrams Entertainment/Communication Connector End Views Infrared Module (U42) Page 584 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21945 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 23637 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 4145 Junction Block - Rear Lamps X3 Junction Block - Rear Lamps X4 Page 506 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 2740 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 17462 Disclaimer Page 1044 Engine Control Module: Connector Views Engine Control Module Connector End Views Engine Control Module X1 Page 6452 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 7865 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 14094 7. Before disconnecting the 16-way connector, inspect for any backed out terminals (2) as shown. Fully seated terminals (1) are shown for comparison. 1. If a backed out terminal (2) is found, identify the terminal(s) on the repair order. 2. Look at the connector in order to identify the number of the cavity with the backed out terminal. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List in SI. 8. Use the following procedure to disconnect the 16-way electrical connector: 1. For 2ML70 Only: Disconnect the 24-way electrical connector. 2. Release and hold the slide lock on the wiring harness connector. 3. Rotate the connector lever and remove the connector from the component. 9. Repair or replace the terminal(s) as necessary using the following procedure: Page 5469 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 7199 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 15678 1 - Wheel Speed Sensor (WSS) - Left Rear (JL4) 2 - Wheel Speed Sensor (WSS) - Right Rear (JL4) Page 19822 Page 1149 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 120 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 2088 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 13896 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement. Page 7906 Vehicle Zoning Strategy Truck Zoning Page 953 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 12084 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 16033 Fuse: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 9178 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 5789 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 15257 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Page 9400 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 7588 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 7273 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 12723 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 12555 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 11915 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 9611 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 2933 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (7) from the camshaft position (CMP) sensor wiring harness jumper. 2. Remove the water pump. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor and wiring harness jumper from the engine front cover. 5. Disconnect the CMP sensor wiring harness jumper from the CMP sensor. 6. Remove the CMP sensor from the wiring harness jumper. Installation Procedure Page 21461 Page 2835 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 21298 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15693 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement Page 997 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 24182 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 16062 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. Remove the tire from the wheel. Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 3. Remove the tire pressure sensor nut. 4. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Page 21691 Driver Door Switch (DDS) X1 (AN3/DL3) Driver Door Switch (DDS) X2 (AN3/DL3) Page 24667 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 19103 Air Bag Deactivation Switch: Service and Repair Inflatable Restraint Instrument Panel Module Disable Switch Replacement Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub: Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 260 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 11255 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Clutch: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 14399 Drive/Propeller Shaft: Service and Repair Two-Piece Propeller Shaft Replacement Two-Piece Propeller Shaft Replacement Tools Required J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 3. Reference mark the front propeller shaft to the transmission or transfer case (slip yoke type) or to the transmission pinion yoke (universal joint type). 4. Remove the clamp (2) securing the boot (3) to the front propeller shaft stub shaft (4) and the rear propeller shaft slip yoke (1) by prying up the exposed end of the clamp (2) using a flat-bladed tool, if applicable. Hood Hinge Replacement Hood Hinge: Service and Repair Hood Hinge Replacement Hood Hinge Replacement Page 6670 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 14818 Shift Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. Important: * When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall Page 3770 Notice: Refer to Fastener Notice. 5. Install the oil pan bolts. Tighten the bolts alternately and evenly to 11 N.m (97 lb in). 6. Install the catalytic converter. 7. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 N.m (18 lb ft). 8. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 6958 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 458 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 9210 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 8303 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 15108 Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Notice: Refer to Fastener Notice. 3. Install the speed sensor bolt (1). Tighten bolt to 12 N.m (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Page 5967 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 16230 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 23949 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 9787 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 21772 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Page 21622 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 8330 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Diagrams Steering Mounted Controls Assembly: Diagrams Secondary/Configurable Control Connector End Views Steering Wheel Control Switch Assembly - Left (K34/KA9) Steering Wheel Control Switch Assembly - Right (UK3) Page 10962 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 358 Electronic Brake Control Module (JH6/JH7) Page 2159 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 21474 Scuff Plate: Service and Repair Front Side Door Sill Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Plate Replacement (Regular Cab/Crew Cab) Page 6956 Air Flow Meter/Sensor: Connector Views Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 3688 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the drain plug and drain the engine oil in a suitable container. 3. Remove the oil filter. 4. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the oil filter gasket with clean engine oil. Notice: Refer to Fastener Notice. 2. Install the oil filter. Tighten the filter to 30 N.m (22 lb ft). Page 4907 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 4597 Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement - without Air Conditioning Drive Belt Idler Pulley Replacement - without Air Conditioning Removal Procedure 1. Loosen the idler pulley bolt. 2. Remove the drive belt. 3. Remove the idler pulley. Installation Procedure 1. Install the idler pulley. 2. Install the idler pulley bolt until snug. 3. Install the drive belt. Notice: Refer to Fastener Notice. 4. Tighten the idler pulley bolt. Tighten the bolt to 50 N.m (37 lb ft). Page 20222 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Service and Repair Power Take-Off Switch: Service and Repair Power Take-Off Switch Replacement A/T - Torque Converter Replacement Information Torque Converter: All Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Page 23915 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 17104 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 21357 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Page 3716 Important: The power steering gear inlet hose cannot be routed between the brake lines and the power brake booster during installation. 1. Route the power steering gear inlet hose in the same position it was in prior to removal. 2. Install the power steering gear inlet hose (2) to the power brake booster (1) and hand tighten only. Rotate the power steering gear inlet hose clockwise until the it contacts the power brake booster housing and then hold it in position while tightening it to the fitting specification. Notice: Refer to Fastener Notice. 3. Install the power steering gear inlet hose (2) to the power steering gear. Tighten the fittings to 32 N.m (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Page 8386 Page 12531 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 6966 Page 2772 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 1103 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 5972 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 13322 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (367A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 20284 Page 8134 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 991 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 2191 Page 6971 Page 1908 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 12666 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21635 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 24245 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 13378 Disclaimer Page 21836 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 717 Audible Warning Device Control Module: Diagrams Displays and Gages Connector End Views Chime Module (UL5) Page 2028 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 22448 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 13825 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 983 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Locations Knock Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 14043 Page 2198 Page 1804 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 492 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 16883 Seat Belt Replacement - Center Front Seat Belt: Service and Repair Seat Belt Replacement - Center Front Seat Belt Replacement - Center Front Page 4362 Wheels: Description and Operation Steel Wheel Repair Description Steel Wheel Repair Description Notice: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. Notice: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Page 20389 1. Position the hitch platform to the vehicle. Notice: Refer to Fastener Notice . 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 N.m (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 N.m (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 N.m (74 lb ft). Page 9772 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Exhaust System - Underbody Rattle/Clunk/Rumble Noise Seals and Gaskets: Customer Interest Exhaust System - Underbody Rattle/Clunk/Rumble Noise Bulletin No.: 07-06-05-003 Date: March 08, 2007 TECHNICAL Subject: Exhaust Pipe / Muffler Rumble, Rattle, Moan, Drone, Vibration Noise (Align Exhaust and Install New Exhaust Seals) Models: 2007 Chevrolet Silverado 1500 Series Only 2007 GMC Sierra 1500 Series Only Condition Some customers may comment on an underbody rattle/clunk/rumble noise. Cause This condition may be due to insufficient clearance between the exhaust and transmission crossmember. Correction Measure the clearance between the exhaust pipe and the transmission crossmember. If the clearance is between 15 mm-30 mm (0.59 in-1.18 in), this is not the cause of the customer's concern. Do not proceed with this bulletin. Continue to diagnose the customer's concern. If the clearance is less than 15 mm (0.59 in), realign the exhaust following steps 2-6. Disconnect the Y-pipe outlet from the exhaust muffler assembly. Loosen both the left and right exhaust manifold pipe nuts. It may be necessary to remove the right side 02 sensor to gain access to all the right side exhaust manifold nuts. The left exhaust MUST be torqued first. Tighten the left exhaust manifold pipe bolts in the sequence indicated in illustration "A" above. Tighten: Tighten the bolts to 50 N.m (37 lb ft). Monitor the clearance between the exhaust pipe and the transmission crossmember. It may be necessary to push up on the exhaust while tightening the right exhaust manifold nuts in order to achieve a minimum clearance of 15 mm (0.59 in). Page 503 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Allison - Automatic Transmission Control Module: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Page 17831 Ball Joint: Testing and Inspection Ball Joint Inspection (Upper Ball Joint) Ball Joint Inspection (Upper Ball Joint) Tools Required J 8001 Dial Indicator Set 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is present. If vertical free play is experienced proceed with the following instructions. 3. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation. 4. Support the lower control arm with a floor stand or jack, as far outboard as possible. 5. If a seal is cut or torn, replace the ball joint. 6. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. Refer to Upper Control Arm Replacement (1500) Upper Control Arm Replacement (2500, 3500). 7. Check the wheel bearing for looseness in the wheel bearing is present. Refer to Wheel Bearings Diagnosis. 8. Check the upper ball joint for vertical looseness. 9. Remove the lower shock absorber mounting bolt. This will ensure that the suspension is unloaded. 10. Install and position the dial indicator from J 8001 against the rim of the upper ball joint. 11. Apply downward force to the upper control arm and zero the indicator pointer/pad against the rim of the upper ball joint. 12. Release the arm and check the dial indicator. The dial indicator reading should be no more than 2 mm (0.079 in). If the reading is too high, replace the upper control arm. Refer to Upper Control Arm Replacement (1500) Upper Control Arm Replacement (2500, 3500). Page 13481 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Notice: Refer to Fastener Notice. 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 N.m (92 lb in). 5. Install the control valve assembly. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 10916 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 12957 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 14872 View of the connector when released from the component. View of another type of Micro 64 connector. Page 14294 5. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 6. Wipe all grease away from the face of the CV joint. 7. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 8. Spread the snap ring ears apart using J 8059 (or equivalent). 9. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 10. Discard the old CV joint boot (5). Page 23059 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Page 10382 Fuel Injector: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 1650 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 14502 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 21557 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10235 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 12680 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 16245 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 11166 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 16702 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 9895 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 16284 Junction Block - Right I/P (Wire Entry) (Pin 4B7 To 6B) Junction Block - Right I/P X2 Page 22359 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 2650 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 4602 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing 1. With the vehicle on a level surface, allow adequate drain down time, 2-3 minutes, and measure for a low engine oil level. Add the recommended grade engine oil, and fill the crankcase until the oil level measures FULL on the oil level indicator. 2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure gage or the oil indicator light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: * Engine oil diluted by moisture or unburned fuel mixtures * Improper engine oil viscosity for the expected temperature * Incorrect or faulty oil pressure gage sensor * Incorrect or faulty oil pressure gage * Plugged oil filter * Malfunctioning oil filter bypass valve 4. Remove the oil pressure gage sensor or another engine block oil gallery plug. 5. Install an oil pressure gage. 6. Start the engine and then allow the engine to reach normal operation temperature. 7. Measure the engine oil pressure at the following RPM: 1. 42 kPa (6 psig) minimum, at 1,000 RPM 2. 125 kPa (18 psig) minimum, at 2,000 RPM 3. 166 kPa (24 psig) minimum, at 4,000 RPM 8. If the engine oil pressure is below minimum specifications, inspect the engine for one or more of the following: * Oil pump worn or dirty * Malfunctioning oil pump pressure relief valve * Oil pump screen loose, plugged, or damaged * Excessive bearing clearance * Cracked, porous or restricted oil galleries * Engine block oil gallery plugs missing or incorrectly installed * Broken valve lifters Page 2085 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 15427 Master Cylinder Reservoir Replacement (JH6, JH7) Removal Procedure Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. 1. Apply the park brake and block the wheels. 2. Remove the master cylinder. 3. Drain the master cylinder reservoir. 4. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange. 5. Remove the brake fluid level sensor by carefully depressing the retaining tabs and pushing the sensor through the reservoir. 6. Carefully remove the reservoir retaining pins. 7. Remove the reservoir from the master cylinder by pulling the reservoir straight up and away from the cylinder. 8. Remove the seals from the master cylinder. Installation Procedure 1. Inspect the reservoir for cracks or deformation. If found, replace the reservoir. 2. Clean the reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. 4. Lubricate the new seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Page 18992 Disclaimer Page 8493 4. Reposition the knock sensor sleeve (2) down, away from the knock sensor. 5. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. 6. Remove the knock sensor bolt and sensor. Installation Procedure Page 1854 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 3865 Page 2067 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 1587 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Controls Component Viewst Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 2340 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 17388 X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Page 12598 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 9002 and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 6. Connect a test lamp between the relay coil B+ and the relay coil control circuit. 7. Ignition ON, command the powertrain relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the relay coil control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the relay coil control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 8. Connect a 20A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 9. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 10. If all circuits test normal, test or replace the relay. Component Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Test for 65-110 ohms of resistance between terminals 85 and 86 of the relay. ‹› If the resistance is not within the specified range, replace the relay. 3. Test for infinite resistance between following terminals: * Terminal 30 and 86 * Terminal 30 and 87 * Terminal 30 and 85 * Terminal 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 20A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm of resistance between terminals 30 and 87. ‹› If greater than the specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Relay Replacement (Within an Electrical Center) Relay Replacement (Attached to Wire Harness) * Underhood Electrical Center or Junction Block Replacement * Refer to Programming and Relearning for setup and programming. See: Testing and Inspection/Programming and Relearning Page 8671 Disclaimer Page 3091 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 254 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2412 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Luggage Carrier Replacement Luggage Rack: Service and Repair Luggage Carrier Replacement Luggage Carrier Replacement Page 5387 Page 13754 Page 6581 Vehicle Zoning Strategy Truck Zoning Page 22427 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 11712 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Diagrams Fuel Level Sensor: Diagrams Displays and Gages Connector End Views Fuel Pump and Sender Assembly - Front (Gas) Fuel Pump and Sender Assembly - Rear (Gas +LY6) Page 14224 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 3. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 4. Using an inch-pound torque wrench, measure the amount of torque required to rotate the pinion. Record this measurement for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion oil seal * The differential case bearings * The axle bearings * The axle seals 5. Place an alignment mark between the pinion and the pinion yoke. A/T - Valve Body Reconditioning Info. Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Info. INFORMATION Bulletin No.: 08-07-30-006A Date: October 13, 2009 Subject: HYDRA-MATIC(R) 6L45 (MYA), 6L50 (MYB), 6L80 (MYC) and 6L90 (MYD), Rear Wheel Drive Automatic Transmission Control Valve Body Assembly Reconditioning Models: 2006-2009 Cadillac XLR 2006-2010 Cadillac STS 2007-2009 Cadillac SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2010 Cadillac CTS 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon Denali, Yukon Denali XL 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L45, 6L50, 6L80 or 6L90 HYDRA-MATIC(R) Rear Wheel Drive Automatic Transmission (RPOs MYA, MYB, MYC, MYD) Supercede: This bulletin is being revised to update model years and add 6L45 transmission (RPO MYA). Please discard Corporate Bulletin Number 08-07-30-006 (Section 07 Transmission/Transaxle). The information outlined in this bulletin is designed to provide easy to follow control valve body reconditioning instructions using the new illustrations to simplify reassembly of the 6L45, 6L50, 6L80 and/or 6L90 automatic transmission control valve body assembly. Caution Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Notice After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. Notice Do not reuse cleaning solvents. Previously used solvents may deposit sediment, which may damage the component. Inspection Procedure for Shift Concerns 1. Using the exploded view, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. IF VALVE BODY CLEANING IS NOT REQUIRED, DO NOT DISASSEMBLE THE BORES UNLESS IT IS NECESSARY TO VERIFY MOVEMENT. 2. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. 3. If a valve is restricted and cannot be corrected by cleaning the valve and bore, replace the valve body. Describe the restricted valve on the repair order. Disassembly/Reassembly for Cleaning Debris 1. If a valve is restricted by a metal burr from machining that bore, remove the valve and burr. Inspect the movement in the valve's normal position. If no other debris or restrictions are found, reassemble the valve body and install in the transmission. 2. If the valve body has been contaminated with debris from another transmission component failure, disassemble all bores for complete cleaning of all valve body components. Keeping individual bore parts separated will make reassembly easier. Use the following illustrations for positive identification and location of individual parts. 3. Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Page 1996 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 21619 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Allison - Automatic Transmission Control Module: Service and Repair Allison - Automatic Transmission Transmission Control Module Replacement Page 19523 For vehicles repaired under warranty, use the table. Disclaimer Page 12091 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 3124 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 457 View of the connector when released from the component. View of another type of Micro 64 connector. Replacement Wheels Description Wheels: Description and Operation Replacement Wheels Description Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Important: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Caution: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Notice: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Page 6162 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 15946 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 12832 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 20392 Notice: Refer to Fastener Notice . 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 N.m (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 N.m (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 N.m (74 lb ft). Page 9905 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Service and Repair Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Page 240 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 595 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 5415 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 5441 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 9513 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 6608 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 24226 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 7786 Camshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 23874 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 4140 Junction Block - Right I/P X4 Page 7931 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Diagrams Power Mirror Switch: Diagrams Mirror Connector End Views Outside Rearview Mirror Switch (DL8/DPN) Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 7633 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9277 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 6459 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Exhaust System - Catalytic Converter Precautions Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Page 18002 Customer TPMS Information Page 13802 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13347 Control Module: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (MW7) 1 - Transmission Control Module 2 - Transmission Control Module Connector 3 - Radiator Fan Shroud Page 21849 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 1794 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 5901 Page 10430 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 8202 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 9201 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 529 Page 8454 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 2288 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 13461 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 9790 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 11758 Page 23003 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 11672 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 17639 Steering Angle Sensor: Removal and Replacement Steering Wheel Position Sensor Replacement Page 16487 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Page 2876 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 17912 1. Install the shock absorber. 2. Install the upper shock absorber nut and bolt. Notice: Refer to Fastener Notice. 3. Install the lower shock absorber nut and bolt. * Tighten the upper shock absorber bolts to 115 N.m (85 lb ft). * Tighten the lower shock absorber bolts to 115 N.m (85 lb ft). 4. Remove the support from the rear axle. 5. Remove the safety stands. 6. Lower the vehicle. Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. Page 3500 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Page 7014 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 6799 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 8187 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 14596 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 15911 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 9526 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 10000 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9869 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 13624 Shift Solenoid: Connector Views 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Page 2911 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 17368 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X275 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness Page 21673 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Page 6897 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 3043 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 19697 8. The navigation radio automatically ejects the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 9. Load the update disc into the slot located behind the display screen by inserting it partially until the system pulls it in. 10. The screen "PREPARING TO LOAD SYSTEM SOFTWARE" will be displayed while the update is loading. The update should take approximately 4 minutes. 11. After the system restarts, press the "EJECT" soft key to eject and remove the software update disc. Important Dealers should retain the software update disc for their use. 12. Load the map DVD into the same slot located behind the display screen, DO NOT put in the top slot. 13. Press the "CLOSE" soft key. 14. Press the "OK" soft key. 15. Press the "MENU" hard key. Important The clock will not be displayed until it is confirmed by completing step 16. 16. Turn the engine OFF. Open and close the driver's door. Wait for 10 minutes. Important Due to the load time of the system, there may be a short delay before the "Map Screen" appears. 17. Restart the engine. After the map screen is displayed, verify that the clock is visible and touch the map screen to confirm that it can be scrolled. If the clock does not appear, repeat programming. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 18. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 19. Verify that the destination search area is properly displayed. 1. Press the "DESTINATION" hard key. 2. Press "CHANGE SEARCH AREA" soft key. 3. Select the correct area for the vehicle's location. Warranty Information Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 21372 Carpet: Service and Repair Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 12378554 (Canadian P/N 88901678), may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. - In the USA, call 1-800-955-8591. - In Canada, call 1-800-977-4145. Page 12866 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Locations Crankshaft Position Sensor: Locations Engine Controls Component Views Right Side of Engine 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 325 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 968 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 12884 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 5930 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Center Console End Panel Replacement Console: Service and Repair Center Console End Panel Replacement Center Console End Panel Replacement Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Control Module: Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 12141 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 5241 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. Page 13209 7. Cycle the ignition until Drive or Reverse range is attained. Important: Fluid remains in the external circuits and transmission cavities after draining the transmission. 8. Check the transmission fluid level. Page 9719 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 18777 1 - Window Switch - Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 3 - Door Latch Assembly - Right Rear 4 - Speaker - Right Rear Door 5 - Window Motor Right Rear (A31) Page 22992 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 24461 For vehicles repaired under warranty, use the table. Disclaimer Page 362 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (JH6, JH7) Electronic Brake Control Module Replacement (JH6, JH7) Page 17905 Suspension Strut / Shock Absorber: Service Precautions Right Rear Shock Absorber Removal Notice Notice: When performing a service regeneration on cab chassis vehicles, remove the right rear shock absorber to prevent damage to the component. Failure to remove this component may result in damage to the component. Page 12113 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Engine Controls - MIL ON/DTC P0171/P0174 Diagnostics Vacuum Brake Booster: Technical Service Bulletins Engine Controls - MIL ON/DTC P0171/P0174 Diagnostics INFORMATION Bulletin No.: 08-06-04-016 Date: March 06, 2008 Subject: Diagnostic Information on MIL/SES with DTC P0171 (Fuel Trim System Lean Bank 1) and/or P0174 (Fuel Trim System Lean Bank 2) After Brake Master Cylinder Replacement Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2005-2007 Chevrolet Silverado Classic 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2005-2007 GMC Sierra Classic 2007-2008 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Vacuum Power Brakes (RPOs JD9, JF3, JF7) The purpose of this bulletin is to inform dealer technicians to inspect the brake master cylinder seal anytime the brake master cylinder is removed from the vacuum brake booster. A vehicle may encounter an MIL/SES light set with DTC P0171 (Fuel Trim System Lean Bank 1) and/or P0174 (Fuel Trim System Lean Bank 2) if the seal (1) is damaged or missing. To aid in diagnosis a technician may monitor the Long Term Fuel Trims with a scan tool. If a lean condition exists block off the vacuum supply line or hose to the brake booster. If the fuel trims return to normal the seal may be damaged or missing. Prior to removing the brake master cylinder the brake pedal should be applied several times with the engine OFF until the vacuum is depleted from the brake booster. It is possible that the seal could be sucked into the brake booster if the reserve vacuum is not depleted first. Remove the master cylinder and inspect the seal. Refer to Master Cylinder Replacement (JD9, JF3, JF7) in SI. Disclaimer Page 23584 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 6276 Page 15636 Trailer Brake Controller Module (TBCM) Page 6644 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 15044 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 5477 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 22462 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9349 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 16536 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 10687 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis line. 12. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. 13. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister. 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (1). 16. Remove the fuel/EVAP line clip nut (2). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Page 23865 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 23782 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 7873 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 10990 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 11017 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 1563 Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JH6/JH7) Wheel Speed Sensor (WSS) - Right Front (JH6/JH7) Page 9617 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 20064 Alarm Module: Service and Repair Theft Deterrent Module Replacement Page 5370 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 12653 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 22789 Parts Information The service replacement latch kit will include one latch, one left rail end cover and one right rail end cover as shown in the illustration above. Use the latch with the appropriate rail end cover and discard the extra cover. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4189 * When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system, brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. * When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within 50 mm (2 in) of any radius. * Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed. * When major components are removed from the vehicle when supported on a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and secure the vehicle frame to the hoist pads nearest the component to be removed. Vehicle Jacking * Park the vehicle on a clean, hard, level surface before jacking the vehicle. * Any time you lift the vehicle on one end, chock the wheels at the opposite end. * Use jack stands in order to provide support. * When supporting the vehicle using jack stands, place the jack stands under the side rails or the axle. * When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar or mounting hardware. Page 8659 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 7999 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 16482 X309 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) Page 2287 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 9523 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 15871 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 1909 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 13506 Shift Interlock Solenoid: Diagrams Shift Lock Control Connector End Views A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid Page 10732 Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 6659 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 24235 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 16421 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) Page 10449 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 10370 Fuel Injector: Pressure, Vacuum and Temperature Specifications Fuel Injector Pressure Drop.................................................................................................................. ..............................................................20 kPa (3 psi) Page 16769 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 12177 Page 982 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 17795 3. Install the steering shaft coupling bolt at the steering gear. Tighten the bolt to 47 N.m (35 lb ft). 4. Install the engine shield. 5. Remove anti-rotation pin J 42640 from the steering column lower access hole. Page 9045 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 12834 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 10817 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 289 Memory Seat Module X7 (AN3) Page 6539 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 19337 Page 17304 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness Page 2883 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 21032 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Pressure Manual Valve Position Switch Logic Transmission Fluid Pressure Manual Valve Position Switch Logic Page 18554 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 1965 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 12191 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 4054 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 13765 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 9273 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Locations Crankshaft Position Sensor: Locations Engine Controls Component Views Right Side of Engine 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 6200 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 11596 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9059 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Specifications Piston: Specifications Piston - Piston to Bore Clearance - Production ............................................................................................................. 0.018-0.061 mm 0.0007-0.0024 in Piston - Piston to Bore Clearance - Service ......................................................................................................................................... 0.075 mm 0.0029 in Page 9392 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure Page 17383 Inline Harness Connector End Views X321 Body Harness to Headliner Harness (A48) X322 Inline Harness Connector End Views X322 Body Harness to UPA Jumper Harness (UD7) Page 5805 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 2766 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Diagrams Power Window Relay: Diagrams Window Systems Connector End Views Sliding Rear Window Close Relay (A48) Sliding Rear Window Open Relay (A48) Page 7936 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 7392 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 15928 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12050 Shift Solenoid: Specifications 6L50/6L80/6L90 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Shift Solenoid Valve State and Gear Ratio Page 23159 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 2046 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 5894 Page 6822 Transmission Position Switch/Sensor: Service and Repair Allison - Automatic Transmission Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 18415 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 13083 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 2104 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 8171 Page 490 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 10148 1. Install the air cleaner outlet resonator to the MAF/IAT sensor and throttle body. Notice: Refer to Fastener Notice. 2. Tighten the air cleaner outlet resonator clamp (2) at the throttle body. Tighten the clamp to 4 N.m (35 lb in). 3. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). 4. Connect the PCV hose (1) to the air cleaner outlet resonator. Page 8922 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 9606 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 16665 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 2705 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 7922 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 24487 Washer Fluid Level Switch: Service and Repair Washer Solvent Container Level Sensor Replacement (Chevrolet) A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 9442 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 3815 Refrigerant Oil: Fluid Type Specifications PAG Oil GM P/N 12378526 for United States PAG Oil GM P/N 88900060 for Canada Page 24387 Front Door Window Glass: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Page 24162 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 4001 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module 7 - Fuse Block - I/P Page 5127 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Procedures Steering Angle Sensor: Procedures Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 18024 Tire Pressure Sensor: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 9773 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 13822 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 17056 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 5409 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 4624 Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement Removal Procedure The optional oil cooler is either an integral part of the radiator or a separate unit placed in front of the radiator. The cooler lines and hoses are serviceable. 1. Disconnect the engine oil cooler quick connect fittings. 2. If equipped with regular production option (RPO) L76 (6.0L) engine, perform the following. 1. Open the oil cooler hose clip located on the lower fan shroud. 2. Remove the oil cooler hoses from the clip. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. Page 16068 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 20982 Disclaimer Page 11448 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 13049 4. Tighten the bolt on J 29714-A in order to compress the servo cover. 5. Install the servo cover ring. 6. Remove the J 29714-A. Notice: Refer to Fastener Notice. 7. Install the oil pan bolt. Tighten the bolt to 11 N.m (97 lb in). 8. Raise the transmission. 9. Install the transmission crossmember. 10. Remove the transmission jack. 11. Install the heat shield and bolts. Tighten the bolts to 17 N.m (13 lb ft). 12. Install the catalytic converter pipe. 13. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 14. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 16898 Page 17072 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 6311 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11734 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Service and Repair Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Panel/Window Garnish Molding Replacement (Crew Cab) Page 7343 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 14157 6. Clean the drain plug. Installation Procedure Notice: Refer to Fastener Notice. 1. Install the rear axle drain plug. Tighten the rear axle drain plug to 33 N.m (24 lb ft). 2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. 3. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 4. Lower the vehicle. Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Page 17863 Transmission Support Crossmember Replacement (4WD 1500/2500) Transmission Support Crossmember Replacement (4WD 1500/2500) Page 6476 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 14904 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 12665 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 20778 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12765 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. * Tighten the control valve body bolts to 11 N.m (97 lb in). * Tighten the TCC solenoid bolts to 11 N.m (97 lb in). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. Page 324 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 6932 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 1954 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 3721 Page 8937 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 16175 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13603 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 14164 9. Remove the inner pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Installation Procedure 1. Install the outer pinion bearing cup using the J 8611-01, 8.6 inch axle, or the J 7818, 9.5/9.5LD inch axle, or the J 8608 (11.5 inch axle) (2) and the J 8092 (1). Page 24184 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 17852 Page 11829 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 20063 Alarm Module: Diagrams Immobilizer Connector End Views Theft Deterrent Control Module Locations Brake Fluid Level Sensor/Switch: Locations Antilock Brake System Component Views Left Side of the Engine Compartment 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (- MYC) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Page 17155 Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 2421 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Inflatable Restraint Front End Sensor Replacement (1500) Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement (1500) Inflatable Restraint Front End Sensor Replacement (1500) Page 10844 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 10261 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 19424 Disclaimer Page 11625 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Reposition the knock sensor sleeve (3) down, away from the knock sensor. 4. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. Page 12830 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 3823 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed Procedure (Without JL4) Antilock Brake System Automated Bleed Procedure (With JL4). 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes Page 6927 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 20289 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Important: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems. 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gages. Page 10662 Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Regular Cab) Fuel Hose/Pipes Replacement - Chassis (Regular Cab) Removal Procedure Important: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. 3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 6357 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 6165 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 4900 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3121 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13556 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Service and Repair Accumulator HVAC: Service and Repair Accumulator Replacement (Non-HP2) Page 3555 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure Important: Prior to removing the spark plug wire(s) note the correct routing of the wires as required. 1. Remove the appropriate spark plug wire boot(s) (1, 2) from the ignition coil. 1. Twist the spark plug boot 1/2 turn. 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose, in order to remove the spark plug wire boot from the ignition coil. 2. Remove the appropriate spark plug wire boot(s) (2) from the spark plug. (left side shown, right similar). 1. Twist the spark plug boot 1/2 turn. Page 2694 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 12516 Page 17786 Steering Shaft: Service and Repair Steering Shaft Upper Bearing Replacement Steering Shaft Upper Bearing Replacement Tools Required * J 21854-01 Pivot Pin Remover * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter * J 42640 Steering Column Anti-Rotation Pin Removal Procedure Caution: Refer to Restraint System Service Precautions. 1. Remove the steering column. 2. Remove the inflatable restraint steering wheel module coil. 3. Remove the turn signal multifunction switch. 4. Remove the ignition lock cylinder case. 5. Remove the tilt spring. 6. Remove the automatic transmission control. 7. Using compressor J 23653-SIR and adapter J 42137, remove and discard the steering shaft lock plate retaining ring. 8. Remove the following parts from the steering column shaft assembly: 1. The turn signal switch cancel cam position plate (5) 2. The turn signal switch cancel cam (4) 3. The steering shaft upper bearing spring (3) 4. The steering shaft upper bearing inner race seat (2) 5. The steering shaft upper bearing inner race (1) Page 11526 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 16953 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 7823 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 10090 Installation Procedure 1. Remove the caps from the EVAP canister purge solenoid valve and the chassis EVAP pipe. 2. Position the EVAP canister purge solenoid valve tube. 3. Connect the EVAP canister purge solenoid valve tube quick connect fitting (1) to the EVAP canister purge solenoid valve. 4. Connect the EVAP canister purge solenoid valve tube quick connect fitting (2) to the chassis EVAP line. Page 13789 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Allison - Automatic Transmission Fluid Line/Hose: Service and Repair Allison - Automatic Transmission Transmission Fluid Cooler Hose/Pipe Connector Replacement Transmission Fluid Cooler Hose/Pipe Connector Replacement Removal Procedure 1. Disconnect the hose from the transmission oil cooler pipe connector being replaced. 2. Remove the transmission oil cooler pipe connectors (1) and (2). Installation Procedure Notice: Refer to Fastener Notice. 1. Install new transmission oil cooler pipe connectors (1 and 2). Tighten to 25 N.m (18 lb ft). 2. Connect the hose to the transmission oil cooler pipe connectors. Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the radiator grille. Page 10924 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 10954 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Pressure Manual Valve Position Switch Logic Transmission Fluid Pressure Manual Valve Position Switch Logic Garage Door Opener Programming - Universal (One LED) Garage Door Opener Transmitter: Testing and Inspection Garage Door Opener Programming Universal (One LED) Garage Door Opener Programming - Universal (One LED) Important: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitter(s). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than 1 inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. Important: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call 1-800-355-3515 in order to address this problem. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. Training the GDO for Rolling Code Receivers This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. If not successfully programmed, try 2-5 seconds each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call 1-800-355-3515 in order to address compatibility concerns. Erasing Channels To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Page 5139 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 22306 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 17743 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Page 9025 Air Flow Meter/Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 11104 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 4730 4. If installing the old sensor, apply sealant to the threads of the sensor. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 5. Using J 41712, install the sensor. Tighten the sensor to 30 N.m (22 lb ft). 6. Connect the fuel pump/oil pressure sensor electrical connector (3). 7. Check and adjust the engine oil level, if necessary. Page 10057 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 9347 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 6724 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 6727 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 17860 Page 2886 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 13671 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 6. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). Page 2519 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 20320 Models Supercede: This bulletin is being revised to add model years, models and additional information. Please discard Corporate Bulletin Number 00-00-89-008E (Section 00 - General Information). Some customers may want to tow their vehicle behind another vehicle with all FOUR tires on the ground. This is referred to as "dinghy" towing. Towing in this manner is acceptable only on the certain vehicles. The vehicle should be properly equipped and prepared as described below. The passenger cars listed above are the vehicles that CAN be dinghy towed. Passenger cars not listed above are vehicles where dinghy towing is not permitted or recommended. Certain 4WD trucks can be dinghy towed depending on the transfer case option. Rear wheel drive and AWD trucks should NOT be dinghy towed. Refer to the truck models and transfer case options below. Please refer to the applicable vehicle Owner's Manual before towing. Passenger Cars Page 15570 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 19092 20. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 21. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used for the seat belt pretensioner deployment harness. 22. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 23. Twist together one end from each of the wires in order to short the wires. The deployment wires are to remain shorted, and not connected to a power source until you are ready to deploy the seat belt pretensioner. 24. Twist together one connector wire lead to one deployment wire. 25. Inspect that the previous connection is secure. 26. Bend flat the twisted connection. 27. Secure and insulate the connection using electrical tape. 28. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. Page 7274 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 105 For vehicles repaired under warranty, use the table. Disclaimer Page 23942 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 2351 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 4821 Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: * Tearing * Piercing * Arcing * Corroded terminal If corrosion, or arcing are indicated on a spark plug wire boot a terminal, replace the wire and inspect the components connected to the wire. Page 9516 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 23013 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 4207 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 7379 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 5172 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 5192 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 13818 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 12842 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 14221 8. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion pilot bearing (10.5 inch axle) * The pinion oil seal * The differential case bearings * The axle bearings (8.6 inch, 9.5 inch axles) * The axle seals (8.6 inch, 9.5 inch axles) 9. Place an alignment mark between the pinion and the pinion yoke. 10. Install the J 8614-01 as shown. 11. Remove the pinion nut while holding the J 8614-01. 12. Remove the washer. Page 6344 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 8406 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 6240 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 14045 Left Side Control Valve Body Assembly SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Classification Module - Air Bag: Customer Interest SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 6363 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 17883 Steering Angle Sensor: Removal and Replacement Steering Wheel Position Sensor Replacement A/C - Does Not Cool/Can't Change Mode/DTC's Set Multiple Junction Connector: Customer Interest A/C - Does Not Cool/Can't Change Mode/DTC's Set Bulletin No.: 07-01-38-009B Date: November 28, 2007 TECHNICAL Subject: EI07264 - Manual HVAC, Temperature or Mode Actuator Performance, A/C Does Not Cool, Unable to Change Mode, DTC B0228, B0413, B0423, B0433, B3779, B3782 (Diagnose for Intermittent Wiring Connection at RH BEC) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Extended and Crew Cab Models Only with Manual Temperature Control HVAC System (RPO C67) Supercede: This bulletin is being revised to end the need for engineering information and to provide diagnostic procedures to accurately diagnose this condition. Please discard Corporate Bulletin Number 07-01-38-009A (Section 01 - HVAC). Condition This concern only applies to Extended or Crew cab vehicles. If the customer did not bring their vehicle in for this concern, do no proceed with this bulletin. Some customers may comment that the A/C blows hot air or is inoperative. They may also comment that they are unable to change the temperature or HVAC mode of the vehicle. Under these conditions, the actuator has moved to a default position. Refer to the table. Cause Page 11746 Page 14595 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 10291 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Page 24275 Window Switch - Left Rear (Crew Cab +A31/Extended Cab +ABV) Page 18164 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Page 6370 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 5794 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 18736 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 6904 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 20506 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Electrical Symbols Electrical Symbols Restraints - Air Bag Readiness Light On. Parking Brake Cable: All Technical Service Bulletins Restraints - Air Bag Readiness Light On. TECHNICAL Bulletin No.: 09-09-41-005 Date: June 26, 2009 Subject: Air Bag Readiness Light On, Service Air Bag Message, Inflatable Restraint Sensing and Diagnostic Module (SDM) Corrosion (Replace SDM/Cut and Remove Carpet Pad) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the Air Bag Readiness Light is on. There may also be a Service Air Bag Message on the Driver Information Center (DIC). Upon further investigation, the Sensing and Diagnostic Module (SDM) may be corroded. Cause This condition may be caused by an unseated parking brake cable grommet causing water intrusion under the carpet or vinyl floor, resulting in wet padding. Power washing the vinyl floor and/or customer snow boots can introduce water to the padding above the SDM area. As the padding gets wet, water wicks through the padding towards the SDM over time. Over an extended period of time of constant exposure to water with potential salt/calcium and other elements, the SDM surface starts to corrode. Correction 1. Replace the SDM per SI procedures. Refer to Inflatable Restraint Sensing and Diagnostic Module Replacement in SI. 2. Inspect the SDM connector for corrosion. If corrosion is evident, repair or replace the connector. Refer to SIR/SRS Wiring Repairs in SI. 3. Verify the parking brake cable grommet is sealed properly. Important Cut and remove the padding from around the SDM as instructed whenever the SDM is serviced even if no corrosion is evident to prevent future moisture and corrosion to the SDM and connector. 4. Cut and remove padding from the area around and above the SDM. Refer to illustration above. Make an addition cut to remove all of the padding above the SDM. Parts Information Refer to Group Number 16.712 (Inflatable Restraint System) of the GM Parts Catalog for the appropriate service parts. Warranty Information For vehicles repaired under warranty, use the table above. Page 22178 Seat Adjuster Switch - Passenger (AG2 -AN3) Seat Adjuster Switch - Passenger (AN3) Page 11302 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 2760 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 2630 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 7180 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Diagrams Brake Booster Vacuum Sensor: Diagrams Brake Booster Vacuum Sensor (JL4) Brake Booster Vacuum Sensor (JL4) Page 10570 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 15845 Page 4100 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 12807 Page 19514 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Page 7422 Knock Sensor: Connector Views Engine Controls Connector End Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Page 1529 Brake Fluid Level Sensor/Switch: Diagrams Brake Fluid Level Switch Brake Fluid Level Switch Page 16429 X306 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) Page 10228 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 15495 Parking Brake Warning Switch: Diagrams Park Brake Switch Park Brake Switch Diagrams Center Mounted Brake Lamp Bulb: Diagrams Lighting Systems Connector End Views Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) X1 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) X2 Page 16299 Fuse Block - Underhood X4 Page 13790 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 5977 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 5478 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 21432 Glove Compartment: Service and Repair Instrument Panel Compartment Door Assembly Replacement (with RPO SLT) Instrument Panel Compartment Door Assembly Replacement (with RPO SLT) Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Page 5136 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 23651 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 277 Door Module: Electrical Diagrams Door Control Module Schematics Power, Ground and Serial Data Service and Repair Power Take-Off Switch: Service and Repair Power Take-Off Switch Replacement Page 9910 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 10345 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 14905 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 3881 Page 15141 Page 2815 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 2901 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 6617 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 20575 Page 10397 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12525 Page 16218 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Navigation Radio - Various Malfunctions Navigation System: All Technical Service Bulletins Navigation Radio - Various Malfunctions TECHNICAL Bulletin No.: 08-08-44-002B Date: April 14, 2009 Subject: Navigation Radio Clock and/or Clock Tab Do Not Appear or Disappears Intermittently, Split Screen, Points of Interest or Exit List Appears While Driving, Text Color May Be Difficult to See, Address Book Characters May Be Hard to Find, Cannot Scroll Through XM Radio Categories, I Agree Screen Lockouts (Update Navigation Radio with New Software) Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008 HUMMER H2 with Navigation Radio RPO UVB or U3U Supercede: This bulletin is being revised to add additional customer concerns and to update the list of Operating Characteristics the software addresses. Please discard Corporate Bulletin Number 08-08-44-002A (Section 08 - Body & Accessories). Condition Some customers may comment about any of the following conditions: - The clock and/or clock tab does not appear or disappears intermittently on the navigation screen. - A split screen, points of interest or an exit list may appear on the navigation screen while driving. - The text color may be difficult to see on light color backgrounds. - The address book entry characters may be hard to find. - The customer may not have the ability to scroll through the XM radio categories while the vehicle is in motion. - The customer may not be able to scroll through music navigator, MP3 folders, address book, POI's and Turn List when the vehicle is in motion. - "I Agree" screen appears every ignition cycle. - Destination entry screens do not have a "back" button to return to previous page. - Customer is not able to adjust screen brightness while vehicle is in motion. Cause These conditions may be caused by a software anomaly. Correction Using the Tech 2(R), verify that the vehicle is equipped with one of the following radio part numbers: Important If the vehicle is not equipped with one of the following radio part numbers, disregard this bulletin. - 15882766 Allison - Automatic Transmission Transmission Mode Switch: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 8160 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 24110 10. Twist the end of circuit 3040 together with circuit 240. Connect the circuits from the side of the circuit that does not have a terminal. Important: Apply heat to sleeve using a hot air gun or Ultratorch. Apply heat to the center of the sleeve and continue heating for a minimum of 30 seconds. Once the glue starts to melt, slowly rotate the sleeve while applying heat evenly until hot glue is visible outside the sleeve. 11. Using a BLUE colored crimp and seal splice sleeve PN 12089190, crimp the 240/3040 end to the 3040 end. Refer to Splicing Copper Wire Using Splice sleeves in SI, if required. 12. Re-apply tape (1) to the harness. 13. Plug the 40-way connector X1 back into the backside of the LBEC. 14. Verify that there is power to the beacon switch by activating the switch. If the beacon switch light indicator illuminates when the switch is in the ON position and turns off when the switch is in the OFF position, the repair has been performed correctly. 15. Install the instrument panel (I/P) knee bolster. Refer to Knee Bolster Replacement in SI. 16. Install the park brake release handle. Refer to Park Brake Release Handle Assembly Replacement in SI. Claim Information For vehicles repaired under this service update, use the table. Page 9500 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 12632 Shift Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. Important: * When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall Page 11850 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 22531 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 18162 A/C - Control Module A/C Indicator Blinking Control Module HVAC: All Technical Service Bulletins A/C - Control Module A/C Indicator Blinking Bulletin No.: 07-01-38-006 Date: August 20, 2007 INFORMATION Subject: Information For Vehicles with HVAC Control Module A/C Indicator Blinking Due to Low Battery State of Charge Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Manual Temperature Control HVAC System (RPO CJ3) An Air Condition (A/C) button on the Heating, Ventilation and Air Conditioning (HVAC) control module may blink when the A/C system is activated. The blinking indicator will turn to a solid light after cycling the A/C button or ignition key. This condition may be caused by a low battery state of charge on a PREVIOUS ignition key cycle. This condition may be due to situations were an unsold vehicle is parked for long periods of time as part of a dealership's unsold inventory. The A/C indicator begins to flash if the battery voltage falls below 9.5 volts. The low voltage condition may occur during an engine crank or if the vehicle is parked and a normal battery state of charge is not maintained. If the A/C indicator continues to blink, use the Tech 2(R) to help determine the cause. Connect the Tech 2 and build the vehicle. Select Powertrain. Select Engine Control Module (ECM). Select Data Display. Select Cooling/HVAC data. Make sure that there has been an A/C request signal. History should indicate any causes. If necessary, refer to SI for further information on HVAC system diagnostic procedures. Page 5223 Fan Shroud: Service and Repair Engine Coolant Fan Upper Shroud Replacement Engine Coolant Fan Upper Shroud Replacement (Mechanical) Removal Procedure 1. Loosen the air cleaner outlet duct clamps from the throttle body. 2. Loosen the air cleaner outlet duct clamps from the mass airflow sensor(2). 3. Remove the air cleaner outlet duct. 4. If equipped remove the throttle body heater hose retainer from the fan shroud. 5. If equipped remove the inlet radiator hose retainer from the fan shroud. 6. Remove the fan shroud retainers. Page 18628 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Right Side Air Temperature Sensor Replacement - Lower Right Side Page 1009 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10206 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 23898 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 15269 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Tools Required * J 39544-KIT Torque-Limiting Socket Set, or equivalent * J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution. Important: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. See: Brake Rotor Thickness Measurement * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Brake Rotor Assembled Lateral Runout Measurement 1. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. Page 2961 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Power and Grounding Component Views Fuse Block: Locations Power and Grounding Component Views Power and Grounding Component Views Left Side of the Engine Compartment 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (- MYC) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Engine Harness Jumper to Engine POA Harness Diesel Page 3014 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 22593 Passenger Door Switch (PDS) X1 (AN3/DL3) Passenger Door Switch (PDS) X2 (AN3/DL3) Page 437 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10593 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 10045 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 17419 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2366 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 10571 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 18863 Disclaimer Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Page 1781 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 22907 Cruise Control: By Symptom Technical Service Bulletin # 09-08-68-001 Date: 091114 Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 14933 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 2673 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 16097 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 11295 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8918 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 6639 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 17589 If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Memory Steer Description Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Page 11400 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 24376 Disclaimer Page 7800 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 7979 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 3866 Fuse: Locations I/P Fuse Block Fuse Block - I/P, Label Page 11987 Page 13858 Torque Converter Cover: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Transmission Converter Cover Replacement Page 15750 Positive: Service and Repair Battery Positive Cable Fuse Replacement (w/Auxiliary Battery) Battery Positive Cable Fuse Replacement (w/Auxiliary Battery) Removal Procedure 1. Disconnect the auxiliary battery negative cable. 2. Remove the mega fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 16165 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 12888 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 16765 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 6594 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 22826 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 10559 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 5430 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 7808 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 8985 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 15281 4. Compare the lowest thickness measurement recorded to the following specifications: - Brake rotor minimum allowable thickness after refinishing 37.0 mm (1.457 in) - Brake rotor discard thickness 36.50 mm (1.437 in) - Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.10 in) - Brake rotor discard thickness 28.0 mm (1.10 in) - Brake rotor minimum allowable thickness after refinishing 18.5 mm (0.728 in) - Brake rotor discard thickness 18.0 mm (0.709 in) - Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.102 in) - Brake rotor discard thickness 27.50 mm (1.083 in) - Brake rotor minimum allowable thickness after refinishing 29.0 mm (1.142 in) - Brake rotor discard thickness 28.50 mm (1.122 in) 5. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after refinishing specification, the rotor may be able to be refinished, depending upon surface and wear conditions which may be present. 6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specification, the rotor may not be refinished. 7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification, the rotor requires replacement. Brake Rotor Thickness Variation Measurement Brake Rotor Thickness Variation Measurement Caution: Refer to Brake Dust Caution. Important: Any disc brake rotor that exhibits thickness variation exceeding the maximum acceptable level must be refinished or replaced. Thickness variation exceeding the maximum acceptable level can cause brake pulsation. 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (JD9, JF3, JF7) Front Disc Brake Pads Replacement (JH6, JH7) and/or Rear Disc Brake Pads Replacement (JD9) Rear Disc Brake Pads Replacement (JH6, JH7). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the thickness of the brake rotor at four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each measurement. 4. Calculate the difference between the highest and lowest thickness measurement recorded to obtain the amount of thickness variation. 5. Compare the thickness variation measurement to the following specifications: Brake rotor maximum allowable thickness variation: 0.025 mm (0.001 in) Brake rotor maximum allowable thickness variation: 0.009 mm (0.0004 in) Important: Whenever a brake rotor is refinished or replaced, the assembled lateral runout (LRO) of the rotor must be measured to ensure optimum performance of the disc brakes. 6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing or replacement. Page 16764 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4135 Part 2 Electrical Center Identification Views Junction Block - Right I/P, Top View Junction Block - Right I/P (Wire Entry) Page 6693 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1) from the HO2S pigtail electrical connector. 4. Remove the HO2S pigtail electrical connector clip (2) from the frame. 5. Remove the HO2S (4). Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 21689 1 - Door Lock Switch - Passenger 2 - Door Latch Assembly - Passenger 3 - Speaker - Right Front Page 10885 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Page 6223 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 9909 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 7223 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 15265 The list shown is of labor operations for brake service. Disclaimer Page 12059 Locations Battery Current Sensor: Locations Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor Page 13412 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the manual shift shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until the seal is seated at the bottom of the bore. Power Take-Off Cover Gasket Replacement Power Take-Off Cover Gasket Replacement Removal Procedure 1. Remove 6 bolts (3). 2. Remove the power take-off (PTO) cover (2) and gasket (1). Discard the used gasket. 3. Ensure the PTO gasket face on the transmission case is free of all foreign material, nicks, and scratches. Installation Procedure 1. Install the new PTO cover gasket (1) and cover (2). Notice: Refer to Fastener Notice. 2. Start the top-center bolt (3) first. Install the other 5 bolts. Tighten all bolts to 43 N.m (32 lb ft). Rear Propshaft Shaft Seal Replacement Rear Propshaft Shaft Seal Replacement Tools Required * J 24171-A Seal and Dust Shield Remover * J 43782 Rear Seal Installer Removal Procedure Page 18367 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 5420 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 7224 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 6419 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 5335 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 13700 7. Install the clips on the cable to the floor panel reinforcement. 8. Lower the vehicle and ensure that the steering column shift lever is still in the park position. 9. Install the cable grommet to the floor panel. Important: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. 10. Install the range selector cable to the support. Page 1938 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 12976 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 23090 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 6413 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 4715 1. Lubricate the exterior of the NEW seal with clean engine oil. 2. Using J 35468 and a hammer, install the crankshaft front oil seal. 3. Ensure the crankshaft front oil seal is flush and square to the engine front cover. 4. Install the crankshaft balancer. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Input Speed Sensor (ISS) Harness Page 12480 Clutch Control Solenoid Valve: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 3. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) Page 15745 9. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 10. Remove the generator battery jumper cable nut (3) from the mega fuse holder. 11. Remove the generator battery jumper cable terminal (2) from the mega fuse stud. 12. Remove the auxiliary battery positive cable from the mega fuse holder. 13. Disconnect auxiliary battery positive cable electrical connector (1) from the auxiliary battery relay. 14. Reposition the auxiliary battery positive cable boot (5). 15. Remove the auxiliary battery positive cable nut (4) and cable from the battery relay. 16. Remove the auxiliary battery positive cable retainer (2) from the stud on the front of dash. 17. Remove the auxiliary battery positive cable push nuts (6). Page 12750 Page 24460 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Page 15754 Positive: Service and Repair Battery Positive Cable Fuse Replacement (w/Single Battery) Battery Positive Cable Fuse Replacement (w/Single Battery) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the fuse cover. 3. Remove the starter solenoid cable nut (1) from the fuse stud. 4. Remove the starter solenoid cable terminal (2) from the fuse stud. Page 12538 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6538 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 10994 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 10709 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Disconnect the fuel fill pipe recirculation line quick connect fitting (2) from the evaporative emission (EVAP) rear hose. 11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure Page 2757 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 6807 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 11739 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 11737 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 9357 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 7790 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 12096 View of the connector when released from the component. View of another type of Micro 64 connector. Page 7341 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Pressure Regulator Replacement Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Page 11847 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 454 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 9889 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 13626 Shift Solenoid 1 (SS1) Shift Solenoid 2 (SS2) Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 6473 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement Tools Required j 35621-B Rear Main Seal Installer Removal Procedure 1. Remove the flywheel. 2. Insert a flat-tipped screwdriver into the access notches and carefully pry the seal from the housing. 3. Discard the seal. 4. Clean off any dirt or rust in the area. Installation Procedure 1. Apply 2 to 3 drops of clean engine oil to the bore of the housing. 2. Apply 2 to 3 drops of clean engine oil to the outside diameter of the engine flywheel pilot flange. 3. Apply 1 drop of clean engine oil to the outside diameter of the flywheel locator pin. 4. Apply 2 to 3 drops of clean engine oil to the crankshaft seal surface. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 17145 Junction Block - Left I/P X2 (Pin E3 To P5) Junction Block - Left I/P X3 Page 11893 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Electrical Symbols Electrical Symbols SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Classification Module - Air Bag: Customer Interest SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Drive Belt Idler Pulley Replacement - Right Side Idler Pulley: Service and Repair Drive Belt Idler Pulley Replacement - Right Side Drive Belt Idler Pulley Replacement - Right Side Removal Procedure 1. Loosen the idler pulley bolt. 2. Remove the drive belt. 3. Remove the idler pulley. Installation Procedure 1. Install the idler pulley. 2. Install the idler pulley bolt until snug. 3. Install the drive belt. Notice: Refer to Fastener Notice. 4. Tighten the idler pulley bolt. Tighten the bolt to 50 N.m (37 lb ft). Page 12852 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 17207 For vehicles repaired under warranty, use the table. Disclaimer Page 24220 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission: * The torque converter clutch solenoid (1) * The pressure control solenoid (2) * The internal wiring harness (3) * The 2-3 shift solenoid (4) * The 1-2 shift solenoid (5) * The transmission fluid pressure manual valve position switch (6) * The 3-2 shift solenoid (7) * The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wiring harness electrical connectors from the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub: Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 7105 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 3086 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 5970 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 15140 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (JH6, JH7) Electronic Brake Control Module Replacement (JH6, JH7) Page 8194 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 13316 Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 2 (PCS2) Pressure Switch Manifold (PSM) A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 1859 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Diagram Information and Instructions Vanity Lamp: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 6901 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 4804 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 12057 Page 15379 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the J 45405, by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Important: Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Important: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405. 11. Install the tube nuts on the brake pipe, noting their orientation. Page 23308 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11170 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 19756 For vehicles repaired under warranty use, the table. Disclaimer Page 14549 Control Module: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Control Module (TCM), Engine Side Page 12664 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 9170 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 13828 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8208 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 20536 Auxiliary Step / Running Board: Technical Service Bulletins Body - Assist Step Installation Modification INFORMATION Bulletin No.: 08-08-61-003 Date: February 26, 2008 Subject: Modification Procedure for Assist Step Bracket Installation Due to Underbody Interference Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Modification to the right hand second assist step bracket may be necessary for installation due to interference to the underbody. Procedure 1. Modify assist step bracket to create additional clearance between the assist step bracket and the cross-sill bracket. Modify the bracket following the dimensions in the illustration above. 2. Follow the manufacturers specifications for repainting. For the proper refinish materials refer to the 2008 GMWI5406 GM Globally Approved Refinish Materials information. The refinish materials information is now online at the GMGOODWRENCH WEB SITE*. Printed books have been discontinued. To access the site follow these steps: ^ Go to www.gmgoodwrench.com. Page 24558 Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved. - GM dealers and Canadian Saturn/Saab retailers should use GMVIS. - Saturn US retailers should use the 'Investigate Vehicle History' link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports - Export dealers - sent directly to dealers The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information GM, Saturn Canada Only: Parts required to complete this recall are to be obtained from General Motors Service and Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. This part is not eligible for RIM Management. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Saturn US Only: A pre-shipment of the required parts to perform this recall has been sent to involved Saturn US retailers from Saturn Service Parts Operations (SSPO). Jumper Harness with In-Line Fuse Page 23870 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 13770 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. A/T Controls - DTC P1825/P182E or P1915/MIL ON Shift Cable: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 21699 Power Vacuum Brake Booster Replacement (Non-Adjustable Pedals) Vacuum Brake Booster: Service and Repair Power Vacuum Brake Booster Replacement (Non-Adjustable Pedals) Power Vacuum Brake Booster Replacement (Non-Adjustable Pedals) Page 16126 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 12571 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 8305 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Locations Trunk / Liftgate Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 22471 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 12136 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 15917 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 1377 Passenger Door Switch (PDS) X7 (AN3/DL3) Page 4052 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 5202 Page 6498 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10409 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 11659 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 15245 Brake Pad: Service and Repair Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Caution: Refer to Road Test Caution. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Page 19720 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Page 961 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 7618 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 17321 X303 Body Harness to Driver Seat Harness (-AN3) Page 23913 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 20784 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10932 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 11454 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 8462 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 14751 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 234 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 21641 Body - Door Latches Freezes in Extreme Cold Rear Door Latch: Customer Interest Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. Page 16992 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 2892 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 17993 Notice: Refer to Fastener Notice. Important: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3). Tighten the TORX screw to 1.3 N.m (11.5 lb in). Important: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 1. Apply tire soap to the rubber portion of the valve stem (1). 2. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 12233 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 250 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6377 4. Connect the engine wiring harness electrical connector (4) to the CKP sensor. 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. 7. Perform the crankshaft position system variation learn procedure. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 540 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 12017 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. * Tighten the control valve body bolts to 11 N.m (97 lb in). * Tighten the TCC solenoid bolts to 11 N.m (97 lb in). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. Lighting - Turn Signals Have Increased Flash Rate Body Control Module: All Technical Service Bulletins Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15155 Steering Angle Sensor: Diagrams Steering Angle Sensor (JL4) Steering Wheel Speed/Position Sensor Steering Angle Sensor (JL4) Page 19310 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 9040 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12208 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Service and Repair Parking Pawl: Service and Repair Manual Shift Detent Lever and Park Pawl Actuator Replacement Page 1939 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 5790 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 10824 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 8607 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 22834 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Extended Cab) Front Door Opening Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Remove the front and rear door sill plate. Refer to Front Side Door Sill Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Plate Replacement (Extended Cab) or Rear Side Door Sill Plate Replacement (Extended Cab) Rear Side Door Sill Plate Replacement (Crew Cab) . 2. Remove the weatherstrip (1) from the pinch-weld flange (2). Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. Page 7810 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 17573 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 12745 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 8910 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 15251 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Page 16395 X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Page 11319 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 5349 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 6973 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 8117 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 7337 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10639 Page 10202 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 15908 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 17427 For vehicles repaired under warranty, use the table. Disclaimer Page 14776 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 2488 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 7795 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 3601 Drive Belt: Service Precautions Belt Dressing Notice Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Page 24044 Turn Signal/Malfunction Switch X3 Page 16147 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module 7 - Fuse Block - I/P Page 21244 For vehicles repaired under warranty, use the table above. Disclaimer Page 17962 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Page 8094 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 1203 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Crew Cab -10 Series) Page 10769 Page 11144 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 20369 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 5898 Vehicle Zoning Strategy Truck Zoning 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor Assembly, Wiring Harness Side Page 12234 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 4666 Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 3. Remove the fuel pump/oil pressure sensor fitting, if necessary. Installation Procedure 1. If installing the old fitting, apply sealant to the threads of the fitting. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 2. Install the fitting until snug, if necessary. Notice: Refer to Fastener Notice. 3. Tighten the fuel pump/oil pressure sensor fitting. 1. Tighten the fitting to 15 N.m (11 lb ft). 2. Increase torque until the centerline of the fitting (1) is 50 degrees from the centerline of the crankshaft (2). Page 14443 For vehicles repaired under warranty, use the table. Disclaimer Page 11167 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 3784 Fluid - Differential: Removal and Replacement Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (8.6 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Carefully remove the rear axle housing cover (2) and drain the lubricant into a suitable container. 5. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. 6. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation is an indication of extreme wear. Installation Procedure 1. Install a new gasket and the rear axle housing cover (2). Notice: Refer to Fastener Notice. Important: Do not reuse the rear axle housing cover bolts. Page 20904 5. Install the new roll pin that is included in the door handle kit, P/N 88880051. 6. Install the rear side door inside handles. Refer to Rear Side Door Inside Handle Replacement in SI. Customer Information 1. Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition covered under this Special Coverage are to be submitted to the dealer prior to or by July 31, 2011. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Page 6883 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 10376 Page 6038 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 20429 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 1488 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 16933 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 22312 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Page 12016 10. Using J 28458, release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. 12. Inspect the TCC solenoid and wiring harness for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Page 6948 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 13570 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 11848 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 8629 Page 2753 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Interior - Poor Carpet/Rubber Mat Fit/Loose/Bulging Carpet: All Technical Service Bulletins Interior - Poor Carpet/Rubber Mat Fit/Loose/Bulging Bulletin No.: 07-08-110-007B Date: November 30, 2007 TECHNICAL Subject: Front Floor Carpet or Rubber Floor Covering Poor Fit, Loose or Bulging (Install Floor Insulator/Deadener) Models: 2007-2008 Chevrolet Silverado Regular Cab 2007-2008 GMC Sierra Regular Cab with Carpet (RPO B30) or Rubber (RPO BG9) Floor Covering Supercede: This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin Number 07-08-110-007A (Section 08 - Body and Accessories). Condition Some customers may comment on the way the front floor carpet or rubber floor covering (1) fits on the center of the floor tunnel. Others may comment that the floor covering is loose, bulging or just fits poorly on the passenger side. Cause This condition may be caused by a lack of padding under the front floor carpet or rubber floor covering. Correction Install floor insulator/deadener to the top of the floor tunnel using the steps below. For vehicles equipped with a manual 4 x 4 shifter, the shifter knob and trim plate will need to be removed. Refer to Transfer Case Control Lever Replacement in SI. Remove the carpet or rubber floor covering away from the front floor tunnel. Refer to Floor Panel Carpet Replacement (Regular Cab) in SI. Tip The instrument panel (IP) support bracket will need to be removed by prying apart the two trim panels and removing the bolts. Page 21462 Headliner: Service and Repair Headlining Trim Panel Replacement (Regular Cab) Headlining Trim Panel Replacement (Regular Cab) Page 11022 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 17862 Page 15425 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Page 22653 Page 13344 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 21874 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 13943 Transmission Speed Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Input and Output Speed Sensor Replacement Page 22968 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10894 Page 1765 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Page 13933 Transmission Speed Sensor: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 16661 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Body - Outside Door Handle Pulls Out of Base Front Door Exterior Handle: Customer Interest Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information Page 15847 Page 2683 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 8068 A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Entertainment System - DVD Monitor Display Inoperative DVD Player: Customer Interest Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Page 21811 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 9183 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 15525 Page 6462 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Transmission Fluid Temperature Sensor Specifications Page 2398 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 23958 Marker Lamp - Tailgate (RO5) Marker Lamp - Left Rear (Z88) Service and Repair Balance Shaft: Service and Repair Balance Shaft Replacement Tools Required * J 8092 Universal Driver Handle * J 36996 Balance Shaft Installer * J 45059 Angle Meter Removal Procedure 1. Remove the radiator. 2. Remove the air conditioning (A/C) condenser. 3. Remove the lifter pushrod guide. 4. Remove the timing chain and camshaft sprocket. 5. Remove the balance shaft drive gear. 6. Remove the balance shaft driven gear bolt. 1. Use a wrench in order to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 2. Remove the balance shaft bolt. 3. Remove the wrench from the balance shaft. 7. Remove the balance shaft driven gear. Page 14884 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 24174 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 12702 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16031 Vehicle Zoning Strategy Truck Zoning Page 9566 Electrical - 'No Trailer Connected' Message On DIC Trailer Brake Control Module: All Technical Service Bulletins Electrical - 'No Trailer Connected' Message On DIC TECHNICAL Bulletin No.: 09-05-22-004 Date: November 05, 2009 Subject: No "Trailer Connected" Message on Driver Information Center (DIC) at Startup When Trailer is Connected (Reprogram ITBCM) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Equipped with Integrated Trailer Brake (RPO JL1) Condition Some customers may comment that when they connect their trailer, with the engine off, and after they start the engine, the Trailer Connected message is not displayed on the DIC. With the engine running, if the trailer connector is cycled, the vehicle will detect the trailer and display Trailer Connected. This concern should only affect trailers equipped with trailer brakes on a single axle. Cause The trailer brake control system is only compatible with trailers equipped with electric trailer brakes. The system will not work or detect trailers equipped with any other types of brakes such as surge, air or electric-over-hydraulic trailer brake systems. When a trailer is connected, the Trailer Brake Control Module (TBCM) performs a test to determine if the trailer is equipped with electric trailer brakes. If the trailer wiring or electric trailer brake magnets have additional resistance (caused by poor connections, corrosion, improper splices, etc.), the TBCM may not be able to detect the trailer. Correction A revised calibration has been developed to address these issues. Reprogram the Integrated Trailer Brake Control Module (ITBCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Refer to Trailer Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13218 The new thread size 9/16-1a UNF-2A (1) was implemented on 11-29-07 or Julian date 333. Disclaimer Locations Seat Position Sensor: Locations SIR Component Views Driver Seat 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (AN3) Page 7019 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 13697 Shift Cable: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Remove the instrument panel knee bolster. 3. Remove the driver seat. 4. Pull back the carpet and insulation around the driver area. 5. Remove the retainer securing the cable to the steering column. Page 15235 Brake Pad: Testing and Inspection Brake Pad Inspection Caution: Refer to Brake Dust Caution. * Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed from the vehicle. * If replacement is necessary, always replace disc brake pads in axle sets. * Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally occurs at the trailing edge of the disc brake pads. * Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn prematurely. The disc brake pad wear should be approximately even per axle set. * Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor (2). The wear indicator will then produce an audible, high-pitched warning noise during wheel rotation. * Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of the mounting plates. * Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the length of the disc brake pads, replace the disc brake pads. * Verify that any disc brake pad shims that may be required are in place and not damaged or excessively corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance. * Replace the disc brake pads if any have separated from the mounting plates. * Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or otherwise impair disc brake performance. Page 3793 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 1662 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 3903 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 12498 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (367A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Page 14096 5. Repair or replace the terminal(s) as needed. Refer to the instructions in the J-38125 manual. 10. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 11. Slide the new terminal(s) into the correct cavity at the back of the connector until it locks in place. The new terminal(s) should be even with the other terminal(s). 12. Ensure that each terminal is locked in place by gently pulling on the wire. Note The male terminal(s) cannot be repaired as they are an integral part of the transmission control module (TCM). 13. Inspect for bent or misaligned terminal(s) in the transmission half of the electrical connector. ‹› If they are bent, use a suitable tool and apply gentle pressure to straighten them. Indicate on the repair order the terminal number of the male terminal that was bent. ‹› If they are damaged, refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement in SI. 14. Prior to installing the transmission connector, perform the following steps to ensure that the TPA lock is fully seated. Locate the TPA lock in the reassembled transmission connector. Refer to the arrow in the illustration above, which points to a TPA lock. This one is in an unseated position. Using a small flat blade tool, push to seat the TPA until it bottoms out. Verify the TPA is fully seated. - If the TPA is off-center in the check window as shown, then it is only partially seated. Note the large gap at the arrow. Reseat the TPA lock and ensure that it is fully seated. - If the TPA lock is centered in the window as shown, then it is fully seated. The gaps shown by the arrows should be even on both sides. 15. Install the transmission 16-way electrical connector. Page 1122 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 6980 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 1935 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 24540 2. Locate the underhood bussed electrical center (UBEC) (1). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse (1). 4. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to Step 7 in this section of the bulletin 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 9. Secure the UBEC cover on the UBEC. 10. Close the hood. 11. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 12. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 Cadillac CTS 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Page 15358 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Page 2789 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 225 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 11825 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 1818 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 16964 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 7585 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 286 Memory Seat Module X4 (AN3) 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Pressure Manual Valve Position Switch Logic Transmission Fluid Pressure Manual Valve Position Switch Logic Page 11815 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 18688 2. Move the driver's seat to the full forward or rearward position. Carpet and cutout flap (2) shown with the driver's seat removed from the vehicle for illustration purposes only. Seat removal is NOT required to gain access to the acoustical pad (3). 3. Lift the cutout flap (2) in the carpet or vinyl to gain access to the acoustical pad (3) that covers the SDM. Seat removed for illustration purposes only. 4. Using your hand, tear away and remove the acoustical pad (3) that covers the SDM (4). Ensure that no acoustical pad remains over, or in contact with, the SDM (4). 5. Lower the carpet or vinyl cutout flap over SDM (4) and adjust the driver's seat to the customer-desired position. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. Page 14834 Locations Dimmer Switch: Locations Lighting Systems Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 5438 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12541 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1336 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Page 396 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 9671 Page 21883 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 4910 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 22928 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 17360 Page 8544 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 21825 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 11759 Page 9454 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 5105 Radiator Cooling Fan Motor Relay: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Diagram Information and Instructions Door Module: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 625 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Locations Headlamp Dimmer Switch: Locations Lighting Systems Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 19958 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Page 22972 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 11032 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 8314 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 22966 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 6887 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 10966 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 13320 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Recall - Heated Windshield Washer Module Short Circuit Technical Service Bulletin # 08048C Date: 090429 Recall - Heated Windshield Washer Module Short Circuit SAFETY Bulletin No.: 08048C Date: April 28, 2009 Subject: 08048C - Heated Windshield Washer Module Short Circuit - Add Wire Harness Models: 2006-2008 Buick Lucerne 2008 Buick Enclave 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Acadia, Sierra, Yukon, Yukon XL 2006-2008 HUMMER H2 2007-2008 Saturn OUTLOOK Equipped with Heated Washer Fluid System .............................................................................................................................................................. .................................................................................. Supercede: The service procedure in this bulletin has been revised to include verification that the fluid system dispenses heated fluid. Please discard all copies of bulletin 08048B, issued October 2008. .............................................................................................................................................................. .................................................................................. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2006-2008 model year Buick Lucerne; Cadillac DTS; HUMMER H2 vehicles; 2007-2008 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK vehicles; and 2008 model year Buick Enclave vehicles equipped with a heated washer fluid system. A short circuit on the printed circuit board for the washer fluid heater may overheat the control-circuit ground wire. This may cause other electrical malfunctions, create an odor, or cause smoke. In rare cases, it may cause a fire. Correction Dealers/retailers are to install a wire harness with an in-line fuse. Vehicles Involved Involved are certain 2006-2008 model year Buick Lucerne; Cadillac DTS; HUMMER H2 vehicle; 2007-2008 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK vehicles; and 2008 model year Buick Enclave vehicles equipped with a heated washer fluid system and built within these VIN breakpoints: Page 6391 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 23842 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 22433 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 2002 Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CMP sensor, install a NEW O-ring seal onto the sensor. 2. Install the CMP sensor to the wiring harness jumper. 3. Connect the CMP sensor wiring harness jumper to the CMP sensor. 4. Lubricate the O-ring seal with clean engine oil. 5. Install the CMP sensor and wiring harness jumper to the engine front cover. Notice: Refer to Fastener Notice. 6. Install the CMP sensor bolt. Tighten the bolt to 10 N.m (89 lb in). 7. Install the water pump. 8. Connect the engine wiring harness electrical connector (7) to the CMP sensor wiring harness jumper. Page 19717 Page 4850 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Page 13442 Notice: Refer to Fastener Notice. 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 N.m (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 7781 Page 9022 Page 15393 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Important: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Front Brake Hose Replacement (JD9, JF3, JF7) Front Brake Hose Replacement (JD9, JF3, JF7) Page 23941 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 14292 18. Inspect the inboard stroke position. - Measurement A for the 1500 models should be 170 mm (6 11/16 inch). - Measurement A for the 2500, 3500, should be 178 mm (7 inch). 19. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement See: Service and Repair. Page 7400 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 24452 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Page 23378 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 7344 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 7779 Page 214 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 8167 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 8825 For vehicles repaired under warranty, use the table. Disclaimer Page 14856 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7989 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 9486 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 4406 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the wheel stud from the hub flange using the J 43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Page 23347 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the negative battery cable. 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 2022 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 16331 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 10782 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 10969 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 6857 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 10539 Page 12148 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9929 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 980 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 17364 X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Page 14810 Shift Solenoid 1 (SS1) Shift Solenoid 2 (SS2) Page 9497 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13415 1. Remove the torque converter from the transmission. 2. Remove any of the 10 bolts (1), bolt heads shaded, where leakage at the bolt head is suspected. Important: The bolts (1) have a removable seal under the flanged head. 3. Remove and discard seals from bolts removed. Installation Procedure 1. Install new seals on any removed bolts (1). Notice: Refer to Fastener Notice. 2. Install any bolts (1) removed. Tighten bolts to 56 N.m (41 lb ft). 3. Install the torque converter into the transmission. Page 6907 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18966 Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 6432 Intake Air Temperature Sensor: Diagrams Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Rear Object Sensor Housing Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement Rear Object Sensor Housing Replacement 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Page 3943 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Driver Information Display Switch Replacement (without RPO SLT) Driver/Vehicle Information Display: Service and Repair Driver Information Display Switch Replacement (without RPO SLT) Driver Information Display Switch Replacement (without RPO SLT) Page 4667 4. If installing the old sensor, apply sealant to the threads of the sensor. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 5. Using J 41712, install the sensor. Tighten the sensor to 30 N.m (22 lb ft). 6. Connect the fuel pump/oil pressure sensor electrical connector (3). 7. Check and adjust the engine oil level, if necessary. Page 5846 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 11689 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 2693 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 7992 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 17570 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 11270 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Locations Steering Angle Sensor: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 22914 Page 11307 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 16767 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 11845 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 23489 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 8626 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 12973 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 12321 Control Module: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Control Module (TCM), Engine Side Page 14118 16. Lower the vehicle. 17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 18. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Fuse Block Inspection of Fuse Block - I/P (Left Side) for Loose Connector X1 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Disconnect Caution and Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side fuse block as shown. 4. Inspect connector X1 (1) on the back of the fuse block for a loose connection as shown. Secure the connector as needed. 5. Install the left side fuse block. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness Near Park Brake Pedal Assembly Chafed IP Wiring Harness Near Park Brake Pedal Assembly The above condition may cause one or more of the following fuses to open: - 60A - MBEC1 (#72) (Underhood) - 30A - AMP (#40) (Underhood) - 15A - RDO (#41) (Underhood) - 10A - IPC (#46) (Underhood) - 15A - AIRBAG BATT (#51) (Underhood) - 10A - DSM (Left side of IP) Five Areas of Potential Contact Have Been Identified Five areas of potential contact have been identified: Page 15726 Auxiliary Battery Relay: Diagrams Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X1 (TP2) Page 4297 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 712 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Headlamp Switch Replacement (with RPO SLT) Headlamp Switch: Service and Repair Headlamp Switch Replacement (with RPO SLT) Headlamp Switch Replacement (with RPO SLT) Page 13745 Page 7798 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 19113 1 - Door Frame 2 - Window Switch - Left Rear (A31) 3 - Window Motor - Left Rear (A31) 4 Speaker - Left Rear Door 5 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 6 Door Latch Assembly - Left Rear Right Rear Door (Crew Cab) Page 13639 Shift Solenoid: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Page 4302 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5965 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 17457 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 15146 Page 2446 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (2) from the HO2S pigtail electrical connector (1). 4. Remove the HO2S pigtail electrical connector clip from the engine wiring harness clip (3). 5. Remove the HO2S (3). SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 23430 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 15824 1 - Ignition Coil 8 2 - Ignition Coil 6 3 - Ignition Coil 4 4 - Manifold Absolute Pressure (MAP) Sensor 5 - Throttle Body 6 - Ignition Coil 2 7 - Knock Sensor (KS) - 2 8 - Crankshaft Position (CKP) Sensor 9 - Engine Oil Level Switch 10 - Starter 11 - Valve Lifter Oil Manifold (VLOM) Assembly 12 - Engine Oil Pressure Sensor Right Side of Engine (Diesel) Page 6935 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 7063 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 7007 View of the connector when released from the component. View of another type of Micro 64 connector. Page 1664 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 13551 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 1084 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 6762 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6854 Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. Fuel: Technical Service Bulletins Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. INFORMATION Bulletin No.: 10-06-04-015 Date: December 08, 2010 Subject: General Motors' Position Regarding Use of E15 in Model Year 2007 and Newer Vehicles Models: 2007-2011 GM Passenger Cars and Trucks General Motors' position regarding the Environmental Protection Agency announcement allowing the use of E 15 in 2007 and newer vehicles: - General Motors' remains focused on securing a safe and positive driving experience for our customers. GM believes that the waiver decision by the EPA regarding E 15 could lead to confusion for consumers as to what fuel their vehicle should use. In response, we will continue to encourage our customers to refer to their vehicle Owner Manual for proper fuel designation. The vehicle Owner Manual specifies that fuels containing more than 10 percent ethanol should not be used in GM vehicles that do not have a flex fuel designation. - GM has the largest fleet of flex fuel vehicles on the road today (over 4 million in the U.S.) and these vehicles can safely use ethanol blends of up to 85 percent ethanol. So blends of E 15 (15 percent ethanol), as in the partial waiver announced, are appropriate for these vehicles. However, ethanol blends greater than E 10 should not be used in GM vehicles that do not have a flex fuel designation as they are not designed and certified to run on gasoline consisting of more than 10 percent ethanol-blend volume to avoid any unintended consequences, as per: their Owner Manual. - We believe biofuels, especially E 85 ethanol, are an effective near-term solution to reduce petroleum dependence and the carbon footprint of driving. As the global leader in producing vehicles designed to handle ethanol blends from E 0 to E 85, GM offers 19 flexible-fuel vehicles for the 2011 model year. Disclaimer Page 7114 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 9528 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 16530 For vehicles repaired under warranty, use the table. Disclaimer Page 5211 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Controls Connector End Views Engine Coolant Temperature (ECT) Sensor Page 13384 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 5295 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2149 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure Page 6091 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 5474 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 12093 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 16209 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 2653 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 19091 15. Twist together, bend, and tape the remaining connector wire lead to the remaining deployment wire. 16. Connect the deployment harness to the seat belt pretensioner connector. 17. Route the deployment harness out of the driver side of the vehicle. 18. Disconnect the seat belt pretensioner connector. 19. Cut the seat belt pretensioner connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. Page 13658 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 5492 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Controls Component Viewst Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Page 24173 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 2873 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel drive shaft, if equipped. 4. Remove the wheel bearing and hub assembly. 5. Remove the outer tie rod end from the knuckle. 6. Separate the upper control arm from the knuckle. Refer to Upper Control Arm Replacement. 8. Remove the knuckle from the vehicle. Installation Procedure Page 22346 Rear Seat Cushion Frame Replacement (Crew Cab with A68) Rear Seat Cushion Frame Replacement (Crew Cab with A68) Page 22127 Power Seat Control Module: Diagrams Power Seat Connector End Views Memory Seat Module X1 (AN3) Memory Seat Module X2 (AN3) Page 14728 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 17475 Install the lower B-pillar cover. Parts Information Warranty Information The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. Page 22288 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Page 9545 4. Position the knock sensor heat shield to the engine block and install the bolt. Tighten the bolt to 10 N.m (89 lb in). 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. Page 7174 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 22980 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 1843 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 183 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 20709 For vehicles repaired under warranty, use the table. Disclaimer Page 583 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 7543 Page 6682 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Service and Repair Timing Chain: Service and Repair Camshaft Timing Chain, Sprocket, and Tensioner Replacement Tools Required j 5590 Rear Pinion Bearing Race Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position (CKP) sensor reluctor ring. Installation Procedure Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system Page 966 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 4976 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 4757 Tighten the bolt to 10 N.m (89 lb in). 9. Connect the engine wiring harness electrical connector from the CMP sensor wiring harness jumper. Important: DO NOT reuse the original CKP sensor O-ring seal. 10. Lubricate a NEW CKP sensor O-ring seal with clean engine oil. 11. Install the NEW O-ring seal onto the CKP sensor. Page 2425 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 12118 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 5582 Heat Shield: Service and Repair Floor Panel Heat Shield Replacement Floor Panel Heat Shield Replacement Removal Procedure 1. Remove the catalytic converter. 2. If vehicle has a regular cab, remove the exhaust heat shield nuts. 3. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. 4. If vehicle has extended cab, remove the exhaust heat shield nuts. 5. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. Page 7318 Page 9129 Battery Current Sensor: Diagrams Battery Current Sensor (10 Series) Battery Current Sensor (10 Series) Page 3127 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 22162 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12172 from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. * The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. 4. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. Notice: Refer to Fastener Notice. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). Tighten the bolts to 12 N.m (108 lb in). Page 9450 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 14528 Disclaimer Page 21860 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 3535 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections Page 8832 Method 1 Method 2 Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: All Technical Service Bulletins Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9807 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Page 18163 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 2878 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 10845 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. A/T Controls - DTC P1825/P182E or P1915/MIL ON PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 23650 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 7938 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 11456 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 11552 View of the connector when released from the component. View of another type of Micro 64 connector. Page 2212 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12660 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Locations Air Flow Meter/Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 9038 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 24717 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 5838 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 4820 Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. ...............................................1,200-1,500 ohms per ft Page 664 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer 4L60-E/4L65-E/4L70-E - Automatic Transmission Clutch Control Solenoid Valve: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 9959 Vehicle Speed Sensor: Locations Power Take-Off Power Take-Off (PTO) Component Views Front Frame Rail 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor 4 - Automatic Transmission Input Shaft Speed (AT ISS) Sensor 5 - Automatic Transmission 6 - Vehicle Speed Sensor (VSS) 7 - X124 8 - Power Take Off (PTO) Module 9 - X175 Page 1968 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 22947 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 7767 Auxiliary Body Control Module (XBCM) X1 (Export) Page 8074 Engine Control Module: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: All Technical Service Bulletins Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11432 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 21327 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 6289 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 2101 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 5938 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 2706 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 3905 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 17175 Instruments - Hard to See/Poor Backlighting Instrument Panel Control Module: Customer Interest Instruments - Hard to See/Poor Backlighting Bulletin No.: 07-08-49-029A Date: January 25, 2008 TECHNICAL Subject: Instrument Panel (IP) Gauges/Gages Difficult to Read or See Poor Backlighting (Replace IP and Program) Models: 2007 Chevrolet Avalanche Silverado Suburban Tahoe 2007 GMC Sierra Sierra Denali Yukon Yukon Denali Yukon XL Yukon Denali XL Supercede: This bulletin is being revised to reflect the latest Utility software part number. Please discard Corporate Bulletin Number 07-08-49-029 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) gauges are difficult to read due to poor backlighting. This condition does not affect the IP cluster operation. Correction DO NOT program the service software into existing 2007 clusters. The service software is designed to work only with the 2008 cluster hardware, which includes a new microprocessor. For IP clusters replaced/programmed due to a customer concern of poor backlighting, warranty claims must be submitted using the labor operation listed in this bulletin. Refer to the Warranty Section for more information. Program the replacement IPC using TIS2WEB Pass-Thru Programming. Select "I/PC" from the Supported Controllers table in TIS2WEB to complete the programming. DO NOT select I/PC Set-up. Mileage and/or Engine Hours must be set by the ESC's prior to installing the IP in the vehicle. DENALI CUSTOMER'S ONLY - Please advise the customer that 2008 Denali clusters are not available. In order to correct this condition, a 2008 Yukon or Sierra cluster will have to be installed in the vehicle. The customer must advise the dealer whether they wish to keep the current 2007 Denali cluster or replace it with a 2008 Yukon or Sierra cluster (which will correct the condition). Programming a 2007 cluster with the 2008 service software can drain the battery and potentially cause a "no start" condition. If the customer is dissatisfied with the IP cluster visibility the current (2007) cluster should be replaced with the 2008 hardware/software. Refer to the charts listed in the Parts Information section of this bulletin to determine the new IP cluster and software part numbers. Page 163 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 561 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub: Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 6757 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 9584 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 7835 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6998 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 7773 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Page 22321 Page 14870 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 17299 Page 7901 Page 474 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 10464 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 6095 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Front Side Door Sill Plate Replacement (Extended Cab) Scuff Plate: Service and Repair Front Side Door Sill Plate Replacement (Extended Cab) Front Side Door Sill Plate Replacement (Extended Cab) Page 20168 Method 1 Method 2 Interior - Sun Visor Fails to Stay In Up Position Sun Visor: All Technical Service Bulletins Interior - Sun Visor Fails to Stay In Up Position TECHNICAL Bulletin No.: 09-08-110-013A Date: April 18, 2011 Subject: Sunshade (Sun Visor) Fails to Stay In Position (Re-seat Detent Spring) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to include the 2012 model year. Please discard Corporate Bulletin Number 09-08-110-013 (Section 08 - Body and Accessories). Condition Some customers may comment that the front sunshade (sun visor) doesn't stay in position tightly against the headliner when in the up position and clipped into the center mount. Cause The condition may be caused by the sunshade being over extended (forced) along the slide on rod to the end of its travel. This over extension can cause the detent spring to be pulled off of the flat on the slide on rod and can cause the detent function to be inoperative. Correction In many cases, the detent spring can be re-seated into the correct position. Use the following procedure to correct the condition. 1. Position the sunshade in the forward position and engage the sunshade into the center clip. Page 11622 4. Reposition the knock sensor sleeve (2) down, away from the knock sensor. 5. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. 6. Remove the knock sensor bolt and sensor. Installation Procedure Page 5279 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 23014 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 10927 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 16081 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 23233 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 6368 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 1104 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 11033 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 13048 12. Remove the servo cover and O-ring seal. If the cover is hung up on the seal, use a pick (2) in order to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. 13. Remove the 2-4 servo. 14. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects: * Cracks * Scoring * Burrs and nicks Installation Procedure 1. Install NEW seals onto the servo pistons and the servo cover. 2. Install the 2-4 servo. 3. Install the J 29714-A. Page 14150 Fluid - Differential: Fluid Type Specifications FRONT AXLE (1500 SERIES) SAE 80W-90 Axle Lubricant (GM Part No. U.S. 89021671, in Canada 89021672). FRONT AXLE (1500 HD, 2500, 2500 HD, AND 3500 SERIES) SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. Page 6282 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 6416 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 3070 Vehicle Zoning Strategy Truck Zoning Page 7874 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 19255 Antenna Cable: Service and Repair Radio Antenna Cable Extension Cable Replacement (with RPO SLT) Radio Antenna Cable Extension Cable Replacement (with RPO SLT) Page 7107 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 8594 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 23145 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 23060 Cigarette Lighter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents HVAC - Automatic Compressor Clutch: Diagrams HVAC - Automatic HVAC Connector End Views A/C Compressor Clutch Page 9901 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 11623 Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (2) up and over the knock sensor. Page 14714 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting * Ensure that the lifting equipment meets weight requirements and is in good working order. Always follow the lift manufacturer's instructions. * You may lift and support the front of the vehicle at the front suspension near the wheel assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle as possible. * Ensure that the vehicle is centered on the hoist before attempting to lift. * When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for the rear stabilizer bar. Page 2214 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2124 4. Remove the CKP sensor bolt and sensor. Installation Procedure Important: When installing the CKP sensor, make sure the sensor is fully seated before tightening the bolt. A poorly seated CKP sensor may perform erratically and may set false diagnostic trouble codes (DTCs). Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CKP sensor, install a NEW O-ring seal onto the sensor. 2. Lubricate the O-ring seal with clean engine oil. Notice: Refer to Fastener Notice. 3. Install the CKP sensor and bolt. Tighten the bolt to 10 N.m (89 lb in). Page 11580 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 3963 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 14858 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 5218 7. Disconnect the electrical connectors from the cooling fans. 8. Remove the clip attaching the wiring harness to the shroud. 9. Remove transmission cooler lines bolts from fan shroud. 10. If necessary, open the engine oil cooler line clip and remove the cooler lines from the clip. 11. Remove the cooling fan shroud bolts. 12. Remove the cooling fan and shroud. Installation Procedure Page 15895 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 8942 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Locations Power Seat Control Module: Locations Power Seat Component Views Driver Seat 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (AN3) A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 9510 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 16117 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 15392 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. Page 2682 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 11812 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 16228 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 1023 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 21264 For vehicles repaired under warranty, use the table. Disclaimer Page 23894 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 13801 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 13027 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Locations Hood Sensor/Switch (For Alarm): Locations Immobilizer Component Views Near the Hood Latch 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor - ISRVM Page 4627 14. If equipped with RPO L76 (6.0L) engine, perform the following: 1. Lower the differential carrier. 2. Remove the oil cooler hose adapter bolts (2). 3. Remove the oil cooler hose assembly and gasket. Discard the gasket. 4. Inspect the fittings, connectors, and cooler hoses for damage or distortion. 15. If equipped with RPO LY6 (6.0L) engine, perform the following: 1. Remove the oil cooler hose bracket bolt. (1) 2. Remove the oil cooler hose adapter bolts. (2) 3. Remove the oil cooler hose assembly. Discard the gasket. 4. Inspect the fittings, connectors, and cooler hoses for damage or distortion. Installation Procedure Page 21989 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Page 16330 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 9238 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 12610 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 20041 Speaker - Right Front (UQ5) A/T Shift Lock Control Solenoid Speaker - Right Front (UQ3) A/T Shift Lock Control Solenoid Speaker - Right Front (UQA) Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9583 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 7759 Body Control Module: Diagrams Data Communication Connector End Views Body Control Module (BCM) X1 Page 9794 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 16128 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 11961 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 6667 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 11548 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 9525 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 579 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 6233 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 10207 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 13529 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 23543 Clearance Lamp: Service and Repair Rear Fender Clearance Lamp Replacement Page 9655 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 6862 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 6691 7. Remove the HO2S pigtail electrical connector clip (9) from the fuel line bracket. 8. Remove the HO2S (1). Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (1). Page 8089 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 9672 Oxygen Sensor: Connector Views Engine Controls Connector End Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Page 17597 Alignment: Service and Repair Wheel Alignment Procedures Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: at a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicles straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: * Inspect the tires for the proper inflation and irregular tire wear. * Inspect the runout of the wheels and the tires. * Inspect the wheel bearings for backlash and excessive play. * Inspect the ball joints and tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. * Inspect the vehicle trim height. * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications. Front Caster and Camber Adjustment Front Caster and Camber Adjustment Important: Caster measurements are now relative to ground. 1. The caster and camber adjustments are made by rotating the offset cam bolt and the cam in the slotted frame bracket in order to reposition the control arm. Important: Before adjusting the caster and camber angles, jounce the front bumper 3 times to allow the vehicle to return to normal height. Measure and adjust the caster and the camber with the vehicle at curb height. The front suspension Z dimension is indicated in Trim Heights. Refer to Trim Height Inspection. 2. For an accurate reading, do not push or pull on the tires during the alignment process. Page 15271 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Tools Required j 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution. Important: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. See: Brake Rotor Thickness Measurement * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Brake Rotor Assembled Lateral Runout Measurement 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement. See: Brake Rotor Thickness Measurement 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Brake Rotor Assembled Lateral Runout Measurement 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction. See: Brake Rotor Assembled Lateral Runout Correction 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. Page 16119 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 8248 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 1056 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test Circuit/System Verification Important: On the scan tool, the powertrain relay is referred to as the EC ignition relay. 1. Ignition ON, engine OFF, command the powertrain relay ON and OFF several times using the scan tool output control function. You should either hear or feel the relay click with each command. 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate on at least one test point of each fuse. ‹› If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data list. Circuit/System Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit and ground. ‹› If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 3. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 4. Verify that a test lamp illuminates between the relay coil B+ and ground. ‹› If the test lamp does not illuminate, test the relay coil B+ circuit for a short to ground or an open/high resistance. 5. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground or an open/high resistance. If the circuits test normal Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Page 23077 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7998 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Locations Seat Heater Switch: Locations Power Seat Component Views Memory/Heated Seat Switch 1 - Outside Rearview Mirror (OSRVM) - Driver 2 - Memory/Heated Seat Switch (AN3) Page 21129 Locations Impact Sensor: Locations SIR Component Views Front Sensors +10 Series 1 - Hood 2 - Inflatable Restraint Front Sensor - Left 3 - Inflatable Restraint Front Sensor - Right Left Front of the Engine Compartment (-10 Series) Wipers/Washers - Heated Washer Fluid System Operation Washer Fluid Heater: All Technical Service Bulletins Wipers/Washers - Heated Washer Fluid System Operation Bulletin No.: 07-08-43-009 Date: August 14, 2007 INFORMATION Subject: Heated Windshield Washer Fluid System Operation - Unwanted Activation of the Front Windshield Washers Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Heated Windshield Washer Fluid System (RPO XA7) The purpose of this bulletin is to further explain information found in SI and the Owner's Manual about the operation of the Heated Windshield Washer Fluid System. Operation: Push the heated washer fluid button to activate the heated windshield washer fluid system. This activation begins four heated wash/wipe cycles. The first heated wash/wipe cycle can take up to 40 seconds to occur, depending on outside temperature. After the first wash/wipe cycle, it can take up to 20 seconds for each of the remaining cycles. To end the heated windshield washer/wipe cycle early press the button again to turn off the heated windshield washer fluid system or it will automatically turn off after four wipe cycles have been completed. Diagnostic Tips: If a customer comes in with a comment about unwanted activation of the front windshield washers, first verify that the heated washer fluid switch was not pressed. Some customers may be unknowingly turning on the heated windshield washers. The heated windshield washer button is located below the HVAC controls and if personal items are placed on the center console, it is possible to inadvertently activate the heated washers. If the switch was not pressed and the washers/wipers continue to cycle with no switch input, observe the Wiper/Washer data using the Tech 2(R). When the concern is happening, it will display the "Windshield Washer Switch" as active even though the switch is not being pressed. This may be caused by an intermittent short in the heated washer fluid module. It has been found, during part reviews of the heated windshield washer module at the Warranty Parts Center (WPC), that a large number of parts returned are no trouble found (NTF). Some of these NTF returns may be due to mis-diagnosis or from customers not fully understanding how the heated windshield washer fluid system operates. The information in this bulletin is being provided to help reduce the NTF returns. Disclaimer Page 2742 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 12154 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 10955 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 20321 Note: The vehicles shown must not be towed backwards or transmission damage may occur. Towing Procedure Note: Failure to follow these instructions may result in damage to the transmission. Important: The towing speed as stated in the Owner's Manual should not exceed 104 km/h (65 mph) for 1995-2005 vehicles. In order to properly dinghy tow the vehicle, follow these steps: 1. Firmly set the parking brake. 2. Open the fuse panel and pull the fuse(s) indicated in the Owner's Manual section detailing towing your vehicle. This prevents the instrument panel (IP) and/or electronic PRNDL indicator from draining the battery. 3. Securely attach the vehicle to the tow vehicle. 4. Turn the ignition key to the OFF position, which is one position forward of LOCK. Unlocking the steering column allows for proper movement of the front wheels and tires during towing. For 1997-1999 Cutlass, 1997-2003 Malibu, 2004-2006 Chevrolet Classic and 1999-2004 Alero/Grand Am models, turn the ignition switch to the accessory (ACC) position, which is one position forward of OFF. This position unlocks the transaxle. 5. Shift the transmission to Neutral (N). Note: Service and Repair Global Positioning System Antenna: Service and Repair Global Positioning System (GPS) Antenna Replacement Page 13879 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Body - Power Sliding Rear Window Inoperative Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 17310 X211 Instrument Panel Harness (Y91) Or I/P Extension Harness (-Y91) To Console Harness (Y91/UQA/D07) (Pin C7 To D8) X212 Inline Harness Connector End Views X212 Instrument Panel Harness to Instrument Panel Extension Harness (-Y91) Page 19347 Parking Assist Control Module: Diagrams Object Detection Connector End Views Rear Object Sensor Control Module X1 Rear Object Sensor Control Module X2 Page 22010 Sunroof / Moonroof Drain: Service and Repair Sunroof Housing Rear Drain Hose Replacement Sunroof Housing Rear Drain Hose Replacement Removal Procedure Important: It is only necessary to lower the headlinder. Only do those steps in headlinder replacement that will lower the headlinder enough to grain access. 1. Lower the headliner. Refer to Headlining Trim Panel Replacement (Regular Cab) Headlining Trim Panel Replacement (Extended Cab) Headlining Trim Panel Replacement (Crew Cab). 2. Disconnect the rear sunroof drain hose from the sunroof module rear spigot, right or left side, as needed. 3. Remove the hose clip securing the drain hose to the vehicle, right or left side, as needed. 4. Remove the drain hose from the vehicle, right or left side, as needed. Installation Procedure Page 18231 Instrument Panel Outer Air Outlet Replacement - Right Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (without RPO SLT) Page 14992 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 9208 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 9543 4. Reposition the knock sensor sleeve (2) down, away from the knock sensor. 5. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. 6. Remove the knock sensor bolt and sensor. Installation Procedure Page 13077 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 22361 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 11190 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 16303 Fuse Block - Underhood X5 (Pin A1 To K3) Page 419 Page 6637 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 24724 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 2491 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 12979 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 23581 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 1330 Parking Assist Distance Sensor: Diagrams Object Detection Connector End Views Object Sensor - Left Rear Corner Object Sensor - Left Rear Middle Page 7255 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 13666 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 16603 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 5425 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Locations Parking Brake Warning Switch: Locations Hydraulic Brake Component Views 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Page 9508 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 16755 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 4510 1. Install the pushrods. Important: Be sure that the arrow on the rocker arm support is in the up position. 2. Install the rocker arm supports. 3. Apply lubricant to the following rocker arm contact surfaces: * Pushrod socket (1) * Roller pivot (2) * Valve stem tip (3) Refer to Sealers, Adhesives, and Lubricants for the correct part number. Page 10232 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 7220 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2334 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 2899 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 10200 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 7173 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 2464 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 6431 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 13776 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 21548 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 6219 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 10393 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 1022 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 12703 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 8960 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Binding In many cases, applying the proper lubrication can correct the following conditions: * Binding or sticking door lock cylinders * Difficulty in inserting and removing the keys For lubricating the above components, use lubricant GM P/N 12346241 or equivalent. Do not use penetrating lubricants such as GM P/N 1052949 or WD-40(R). Penetrating lubricants wash out the original lubrication. Penetrating lubricants eventually evaporate, leaving little or no lubricating material. However, when using penetrating lubricants in order to thaw or in order to loosen the lock cylinder components, refer to steps 2-4 in the procedure below for the proper methods of lubrication. Repair lock cylinders frozen in cold weather by using the following procedure: 1. While carefully avoiding damage to the painted surfaces, apply heat to the cylinder with a heat gun. 2. Using a paper clip or a similar item, hold the door shutter open. Force air into the cylinders using compressed air through a blow gun attachment. 3. While holding the shutter door open, inject small amounts of a recommended lubricant into the cylinder. 4. Work the key into the cylinder repeatedly. Wipe away any excess lubrication from the key. Page 2342 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 22434 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 4090 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9054 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Service and Repair Fog/Driving Lamp Bulb: Service and Repair Front Fog Lamp Bulb Replacement (Chevrolet) Page 11299 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 12078 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 8177 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 8600 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 8311 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 4307 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 5839 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 16249 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 6507 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 24582 Washer Fluid Level Switch: Diagrams Wiper/Washer Connector End Views Washer Fluid Level Switch Page 16125 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 24486 Washer Fluid Level Switch: Diagrams Wiper/Washer Connector End Views Washer Fluid Level Switch Page 456 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 9662 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 8354 Page 6405 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 12279 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. 4L60-E/4L65-E/4L70-E - Automatic Transmission Control Module: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (TCM) 1 - Transmission Control Module (TCM) Page 1113 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 10703 4. Inspect for fuel leaks. Page 6280 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 11428 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 21919 Power Seat Control Module: Diagrams Power Seat Connector End Views Memory Seat Module X1 (AN3) Memory Seat Module X2 (AN3) Page 11178 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 5455 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. OnStar(R) - False Crash Detection Customer Calling Emergency Contact Module: All Technical Service Bulletins OnStar(R) - False Crash Detection Customer Calling TECHNICAL Bulletin No.: 08-08-46-002 Date: June 26, 2008 Subject: OnStar(R) Calls Unwanted, False Crash Detection Customer Calling (Reprogram SDM) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with OnStar(R) (RPO UE1) Condition Some customers may comment on receiving unwanted calls from the OnStar(R) Center. Cause During certain extreme vehicle maneuvers, the vehicle SDM may mistakenly detect a crash event and generate a call to the OnStar(R) call Center. The OnStar(R) advisor is connected to the vehicle to see if everyone is alright and if a request for emergency help is needed. Correction A revised SDM Operating System software has been developed to address this issue. Reprogram the Sensing and Diagnostic Module (SDM) with the controller option described as "SDM Sensing and Diagnostic Module" under Operating System using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5412 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 11212 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 14924 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 20305 Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Page 563 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 6914 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 2851 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 1840 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 896 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Page 23010 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 16719 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 21368 If the customer still expresses a concern about the slit show the customer another comparable vehicle. The new body style pickup and utility will have the same floor trim line with the access cover (1) under the left front seat. The access cover should be pulled back and pressed down for the best appearance. Disclaimer Page 7023 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11089 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 13838 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Locations Electronic Brake Control Module: Locations Antilock Brake System Component Views Left Side of the Engine Compartment 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (- MYC) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Page 15770 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Page 7410 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 12688 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 1218 Disclaimer Page 22656 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Page 1069 Page 5766 Page 21521 Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) Rear Window Lower Garnish Molding Replacement (Regular Cab) Rear Window Lower Garnish Molding Replacement (Regular Cab) Page 13836 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 12608 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 11771 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 6893 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 23878 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Diagrams Valve Deactivation Solenoid: Diagrams Engine Controls Connector End Views Valve Lifter Oil Manifold (VLOM) Assembly (-4.8L) Page 14261 6. On axles with a locking differential, remove the shaft part way. Rotate the case until the pinion shaft touches the housing. 7. On axles with a locking differential, use a screwdriver, or a similar tool, in order to enter the differential case and rotate the lock (1) until the lock aligns with the thrust block (2). 8. Remove the brake drum. 9. Push the flange of the axle shaft in toward the differential. Page 6726 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 13405 Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Page 10208 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 15361 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Notice: Refer to Fastener Notice. 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 N.m (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Brake Drum Diameter Measurement Brake Drum: Testing and Inspection Brake Drum Diameter Measurement Brake Drum Diameter Measurement 1. Clean the brake shoe lining contact surface of the brake drum with denatured alcohol or an equivalent brake cleaner. 2. Using a brake drum micrometer calibrated in thousands of an inch, measure and record the largest diameter of the brake drum at 4 or more points, equally spaced around the drum. Ensure that the measurements are only taken within the brake shoe lining contact area and that the micrometer is positioned the same distance from the outside edge of the drum for each measurement. 3. The maximum allowable diameter : Maximum allowable measurement 296.5 mm (11.673 in) 4. If the largest diameter measurement of the brake drum is less than the maximum allowable diameter, the drum may be able to be resurfaced, depending upon surface and wear conditions which may be present. 5. If the largest diameter measurement of the brake drum is equal to or greater than the maximum allowable measurement, the drum requires replacement. Page 5720 Page 2980 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Air Bag System - DTC B0071/B0074/B0081 Code Clearing Seat Occupant Sensor: All Technical Service Bulletins Air Bag System - DTC B0071/B0074/B0081 Code Clearing Bulletin No.: 07-09-41-004 Date: June 13, 2007 INFORMATION Subject: New Procedure for Clearing Passenger Presence System (PPS) and Sensing and Diagnostic Module (SDM) DTCs B0071, B0074, B0081 Models: 2006-2008 Buick Lucerne 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Monte Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Silverado, Suburban, Tahoe 2007-2008 GMC Yukon, Yukon Denali, Yukon XL, Yukon XL Denali A condition exists where the passenger presence system (PPS) may continue to output a fault to the sensing and diagnostic module (SDM) after the PPS has been cleared. The fault may continue to report to the SDM if the buss has not been allowed to go to sleep prior to clearing B0081 DTC in the SDM. If B0071, B0074 or B0081/0F is received, the following procedure should be followed to clear the codes. With the Ignition OFF, open and close the driver door. With a scan tool, clear PPS DTC (B0071 or B0074). While continuing to keep the doors closed, wait 60 seconds with the ignition OFF. DO NOT operate any functions in the vehicle during this time. Verify that the PPS does not have any DTCs. If PPS DTCs exist, please perform the necessary repair. With the scan tool, clear DTC B0081. Disclaimer Page 15350 Page 21897 Door Lock, Window and Lighting System References Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 1100 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 13229 1. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 2. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 3. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 4. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Page 10527 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 589 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 8384 Page 20364 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 11097 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 7359 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 2127 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Reluctor Ring Replacement Crankshaft Position Sensor Reluctor Ring Replacement Tools Required j 5590 Rear Pinion Bearing Race Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position (CKP) sensor reluctor ring. Installation Procedure Page 22218 Page 23070 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 15466 Notice: Refer to Fastener Notice. 3. Install the park brake cable clip bolt. Tighten the bolt to 22 N.m (16 lb ft). 4. Connect the left rear park brake cable (1) to the intermediate cable equalizer bar (2). 5. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling. 7. Adjust the park brake. Refer to Park Brake Adjustment (Disc Brake) Park Brake Adjustment (Drum Brake). Parking Brake Rear Cable Replacement - Left Side (JF3, JF7) Parking Brake Rear Cable Replacement - Left Side (JF3, JF7) Page 4078 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7545 Page 9463 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 3492 1. Loosen the jam nut on the inner tie rod (1). 2. Rotate the inner tie rod (2) to the required toe specification setting. Refer to Wheel Alignment Specifications. Notice: Refer to Fastener Notice. 3. Tighten the jam nut (1) on the tie rod. Tighten the tie rod jam to 75 N.m (55 lb ft). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Locations Discharge Air Temperature Sensor / Switch: Locations HVAC Component Views Upper Front Air Temperature Sensors (CJ2) 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right HVAC Module Front Wheel Speed Sensor Replacement (JD9, JF3, JF7) Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement (JD9, JF3, JF7) Front Wheel Speed Sensor Replacement (JD9, JF3, JF7) Page 5070 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 17960 Page 3895 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 19394 * Park Tilt Mirrors * Smart High Beams Average Fuel Economy Average fuel economy is calculated using the equation: AFE = Distance/Fuel * Distance = The accumulated distance travelled since the last reset of this value * Fuel = The accumulated fuel consumption since the last reset of this value The engine control module (ECM) sends the average fuel economy GMLAN message to the instrument panel cluster (IPC). The value of this mode is retained during ignition OFF and can be changed between English units and metric units by selecting from the driver information center (DIC) options menu. Average Speed Average speed is calculated using the equation: Average Speed = AVS Distance/AVS Time * Distance = The accumulated distance travelled since the last reset of this value * Ignition On = The accumulated ignition on time since the last reset of this value Oil Life Remaining The ECM sends the oil life remaining percentage to the IPC via GMLAN message. The instrument panel cluster receives a GMLAN message indicating the engine oil life remaining. The DIC displays the current percentage of the GM Oil Life System as determined by the ECM. When the oil life remaining percentage drops below 5 percent, the DIC displays CHANGE ENGINE OIL SOON. When the engine oil is changed, reset the GM Oil Life System. Refer to GM Oil Life System Resetting. Fuel Range This message indicates the estimated distance that the vehicle can travel under the current fuel economy and fuel level conditions since the last battery connection to the IPC. Fuel Range is calculated using the equation: Fuel Range = Range Distance/Range Fuel Used. * Range Distance = The accumulated distance travelled since the last reset of this value. * Fuel Used = The accumulated fuel delivered since the last reset of this value The ECM sends the fuel range value to the IPC. The IPC receives a GMLAN message with fuel information. The fuel range value is retained during ignition OFF and can be changed between English and Metric units by accessing the DIC English/Metric menu. The Fuel Range display cannot be reset. LOW is displayed when fuel range is below a predetermined value. Fuel Used The DIC calculates and displays the total amount of fuel used since the last reset operation. You can reset the fuel used mode by depressing and holding the Set/Reset button for more than 3 seconds. The value of this mode is retained during ignition OFF. Instantaneous Fuel Economy (IFE) Instantaneous fuel economy (IFE) is calculated using the equation: IFE = Distance/Fuel Used. * Distance = The accumulated distance travelled for the last 2 seconds * Fuel = The accumulated fuel delivered for the last 2 seconds The IPC receives a GMLAN message from the ECM. The distance information is calculated by the IPC using the vehicle speed information from the ECM. These values are retained during ignition OFF and can be changed between English and Metric units accessing the DIC English/Metric menu. The IFE display cannot be reset. Tire Pressure Monitor The IPC receives a GMLAN message from the tire pressure monitoring (TPM) system for front and rear tire pressure data. The DIC will display the pressure for each of the front and rear tires. When a tire with low air pressure is present, the DIC displays XXXX XXXX TIRE PRESSURE LOW. Trip Time The timer records elapsed time starting from activation. When the DIC displays the timer, pressing the Set/Reset switch for 1 second on the DIC resets the timer. Pressing the Set/Reset button on the DIC switch for approximately 1 second starts and stops the timer. The DIC displays the timer in one of the following formats: Page 3046 Crankshaft Position Sensor: Connector Views Engine Controls Connector End Views Crankshaft Position (CKP) Sensor Page 6602 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 1803 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 12229 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 13042 5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. * The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. * The valve body gasket is identified by a V. Be sure to place the valve body gasket on the valve body side of the spacer plate. 6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. 7. Place the checkball (3) on the spacer plate in the location shown. 8. Place the 3-4 accumulator spring (4) on the spacer plate. 9. Install the spacer plate and related components to the transmission. Notice: Refer to Fastener Notice. 10. Install the spacer plate support and the spacer plate support bolts. Tighten the bolts to 11 N.m (97 lb in). 11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. Page 6112 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 19764 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Page 18266 Blower Motor: Diagrams HVAC - Manual HVAC Connector End Views Blower Motor Blower Motor Control Module X1 Service and Repair Muffler: Service and Repair Muffler Replacement (1500 Series w/4.3L, 4.8L, 5.3L, 6.0L) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Lower the spare tire. 3. Remove the catalytic converter to exhaust muffler nuts. 4. If equipped with a 4.8L engine, perform the following steps, otherwise proceed to step 7. 5. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal. 6. With the aid of an assistant, remove the insulators (1, 2) from the front and rear muffler assembly hangers. Page 7168 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 5651 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3671 Automatic Transmission Fluid and Filter Replacement Automatic Transmission Fluid and Filter Replacement Removal Procedure Important: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. Important: Use a standard strap-type filter wrench to remove the transmission external oil filter. 3. Remove the filter (4) by rotating in the counterclockwise direction. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Notice: Refer to Fastener Notice. 5. Install the drain plug (6) and drain plug seal (5). Tighten the drain plug to 35 N.m (26 lb ft). 6. Refill Transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. Important: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. Page 14295 11. Place a brass drift against the CV joint cage (1). 12. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 15. Repeat this process to remove all six of the balls. 16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 17. Lift out the cage (4) and the inner race. Air Bag System - DTC B0071/B0074/B0081 Code Clearing Seat Occupant Sensor: All Technical Service Bulletins Air Bag System - DTC B0071/B0074/B0081 Code Clearing Bulletin No.: 07-09-41-004 Date: June 13, 2007 INFORMATION Subject: New Procedure for Clearing Passenger Presence System (PPS) and Sensing and Diagnostic Module (SDM) DTCs B0071, B0074, B0081 Models: 2006-2008 Buick Lucerne 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Monte Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Silverado, Suburban, Tahoe 2007-2008 GMC Yukon, Yukon Denali, Yukon XL, Yukon XL Denali A condition exists where the passenger presence system (PPS) may continue to output a fault to the sensing and diagnostic module (SDM) after the PPS has been cleared. The fault may continue to report to the SDM if the buss has not been allowed to go to sleep prior to clearing B0081 DTC in the SDM. If B0071, B0074 or B0081/0F is received, the following procedure should be followed to clear the codes. With the Ignition OFF, open and close the driver door. With a scan tool, clear PPS DTC (B0071 or B0074). While continuing to keep the doors closed, wait 60 seconds with the ignition OFF. DO NOT operate any functions in the vehicle during this time. Verify that the PPS does not have any DTCs. If PPS DTCs exist, please perform the necessary repair. With the scan tool, clear DTC B0081. Disclaimer Page 3078 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 11376 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Body - Power Sliding Rear Window Inoperative Back Window Regulator: Customer Interest Body - Power Sliding Rear Window Inoperative Bulletin No.: 07-08-48-002 Date: March 09, 2007 TECHNICAL Subject: Power Rear Sliding Window (RPO A48) Inoperative, Will Not Open, and/or Will Not Shut (Replace Rear Window Regulator) Models: 2007 Chevrolet Silverado (New Style) 2007 GMC Sierra (New Style) with Power Rear Sliding Window (RPO A48) Condition Some customers may comment that the power rear sliding window is inoperative, will not open, and/or will not shut. Cause This condition may be caused by the cable ball separating from the cable end in either side of the center glass carrier. Correction Do NOT replace the entire rear window assembly. Replace only the rear window regulator, P/N 25782000. Refer to Rear Sliding Window Regulator Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4276 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 12915 from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. * The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. 4. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. Notice: Refer to Fastener Notice. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). Tighten the bolts to 12 N.m (108 lb in). Page 6128 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 22426 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 5047 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 20314 1 - X201 2 - X276 (KA9) 3 - Heated Steering Fuse (KA9) 4 - X277 (KA9) 5 - X275 Page 11445 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 12245 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 20221 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 22778 For vehicles repaired under warranty, use the table. Disclaimer A/C - Compressor/Serpentine Belt Noise Drive Belt: All Technical Service Bulletins A/C - Compressor/Serpentine Belt Noise TECHNICAL Bulletin No.: 07-01-38-010A Date: October 06, 2009 Subject: Air Conditioning (A/C) Compressor and/or Serpentine Belt Noise at Vehicle Start-up (Reprogram Powertrain Control Module (PCM)) Models: 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon Models Equipped With Air Conditioning (RPOs CJ2 or CJ3) Supercede: This bulletin is being revised to update the Condition and Correction information. Please discard Corporate Bulletin Number 07-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on air conditioning (A/C) compressor slugging and/or serpentine belt or pulley rattle noise at vehicle start-up in warmer outside ambient temperature conditions. Others may describe the noise as a belt chirp or as a thumping/grinding noise coming from the A/C compressor at vehicle start-up. Cause This condition may be caused by the A/C compressor trying to move liquid refrigerant through the system. Correction - A revised PCM calibration has been released to address this condition. Reprogram the PCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. - When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. - When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. - During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information Note *Please use Failure Code 93 for any warranty claims submitted using this bulletin. For vehicles repaired under warranty, use the table above. Page 10650 19. If equipped with 4WD perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service. 20. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. 21. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 22. Remove the fuel line bracket bolt (1). 23. Remove the fuel/EVAP line clip nut (2). 24. Remove the fuel/EVAP line clips from the frame and crossmember. 25. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure 1. If equipped with 4WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Notice: Refer to Fastener Notice. Page 23855 Page 1799 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20123 For vehicles repaired under warranty, use the table. Disclaimer Page 9928 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 8272 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 2695 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 6313 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 17653 Notice: Refer to Fastener Notice. 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 N.m (62 lb in). Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. Install the tire on the wheel. Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 12873 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 5358 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 22001 Important: Transfer the air deflector parts to the new air deflector. 1. Position the sunroof air deflector (2) to the sunroof module (3). Notice: Refer to Fastener Notice. 2. Install the screws (1) attaching the sunroof air deflector (2) to the sunroof module (3). Tighten the screws to 2 N.m (18 lb in). 3. Install the actuators screws (1) and actuators (2) to each side sunroof module. Tighten the screws to 2 N.m (18 lb in). 4. Verify that the spring action of the sunroof air deflector is operating. 5. Close the sunroof window. Page 14737 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 12517 Page 6467 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 11187 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 17217 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 13175 Extension Housing: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Case Extension and Gasket Replacement Page 10600 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 23615 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 1087 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12345 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: * M6 X 1.0 X 65.0 (1) * M6 X 1.0 X 54.4 (2) * M6 X 1.0 X 47.5 (3) * M6 X 1.0 X 35.0 (4) * M8 X 1.0 X 20.0 (5) * M6 X 1.0 X 12.0 (6) * M6 X 1.0 X 18.0 (7) Page 11545 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 11381 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 11377 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 10631 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 23662 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 12650 Page 2329 Vehicle Zoning Strategy Truck Zoning Page 9284 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 17131 Page 9607 View of the connector when released from the component. View of another type of Micro 64 connector. Page 16210 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7145 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 11667 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 11851 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 8447 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 8297 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1897 Page 8424 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 2990 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 6603 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 11163 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 13221 2. Remove the transmission fluid cooler hose from the auxiliary oil cooler. 3. Remove the transmission fluid cooler hose from the radiator. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the engine protection shield. 6. Remove the cooling lines from the transmission. 7. Remove the oil cooling lines from the vehicle. Installation Procedure Page 16153 Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 11253 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 12877 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6099 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 1833 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 6396 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 11223 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 8964 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 6251 Camshaft Position Sensor: Connector Views Engine Controls Connector End Views Camshaft Position (CMP) Sensor Page 10290 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Page 2128 Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face the engine front cover. Failure to do so will damage the front cover and the reluctor ring. 1. Install the CKP sensor reluctor ring. 1. Align the keyway on the CKP sensor reluctor ring with the key in the crankshaft. 2. Using J 5590, push the CKP sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. 2. Install the engine front cover. Page 3105 View of the connector when released from the component. View of another type of Micro 64 connector. Electrical - No Start/No Crank/Int Electrical Operations Multiple Junction Connector: Customer Interest Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 21234 Page 1088 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 17098 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 13006 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 10187 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 16397 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Page 22152 Power Seat Motor Position Sensor: Diagrams Power Seat Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Page 5876 Engine Control Module X2 (Pin 31 To 73) Page 21566 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) Seals and Gaskets: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) Tools Required * J 8092 Universal Driver Handle-3/4 in - 10 * J 21128 Axle Pinion Oil Seal Installer (8.6 inch and 9.5 inch LD Axles) * J 23690 Axle Shaft Bearing Installer (8.6 inch and 9.5 inch LD Axles) * J 2619-01 Slide Hammer * J 29709 Wheel Bearing Installer (9.5 inch Axle) * J 29712 Wheel Bearing Remover (9.5 inch Axle) * J 29713 Axle Seal Installer (9.5 inch Axle) * J 44685 Rear Axle Seal and Bearing Remover (8.6 inch and 9.5 inch LD Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch and 9.5 inch LD axles) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure Page 6269 Page 20117 For vehicles repaired under warranty use, the table. Disclaimer Lighting Systems Connector End Views Ambient Light Sensor: Diagrams Lighting Systems Connector End Views Lighting Systems Connector End Views Ambient Light Sensor (C67/C42) Page 16237 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 23899 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 24231 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 4449 1. Install the pushrods. Important: Be sure that the arrow on the rocker arm support is in the up position. 2. Install the rocker arm supports. 3. Apply lubricant to the following rocker arm contact surfaces: * Pushrod socket (1) * Roller pivot (2) * Valve stem tip (3) Refer to Sealers, Adhesives, and Lubricants for the correct part number. Page 23857 Vehicle Zoning Strategy Truck Zoning Page 10609 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 18579 Disclaimer 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Input Speed Sensor (ISS) Harness Page 7363 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 9740 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 21638 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 11833 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 6642 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 4848 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Page 11819 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 9748 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 16258 Fuel Injector Diagnosis (With CH 47976) Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (With CH 47976) Fuel Injector Diagnosis (With CH 47976) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. The CH-47976 is used to test the fuel pump, fuel system leak down, and the fuel injectors. Following the User Guide, CH 47976-11, and the on screen prompts or selections, will indicate the steps required to perform each of the available tests. The tester will perform all of the tests automatically and display results of the test. The results can also be down loaded for storage and printing. Component Testing Fuel Injector Coil Test Verify the resistance of each fuel injector with one of the following methods: * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14 ohms. ‹› If the injectors measure OK, perform the Active Fuel Injector Tester (AFIT) Test Procedure. ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value. The difference between the lowest value and the highest value should be equal to or less than 3 ohms. ‹› If the difference is equal to or less than 3 ohms, refer to AFIT Test Procedure. ‹› If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. Important: * DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling. * Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. AFIT Test Procedure 1. Turn OFF all accessories. 2. Turn OFF the ignition. 3. Install the AFIT. 4. Turn ON the AFIT and select the vehicle. 5. Turn ON the ignition and perform the Injector Test. ‹› If the AFIT aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 6. View the test results. ‹› If any injector exceeds the recommended tolerance, replace the injector(s), E-85 only. All other engine, refer to Fuel Injector Cleaning. Page 14845 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 11735 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 3445 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Extended Cab) Rear Side Door Window Switch Replacement (Extended Cab) Page 2788 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Disconnect the engine wiring harness electrical connector (4) from the crankshaft position (CKP) sensor. Page 2151 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 8748 Body Control Module: Diagrams Data Communication Connector End Views Body Control Module (BCM) X1 Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Page 5902 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 5711 Body Control Module (BCM) X2 Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 15545 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 5186 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 21815 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Service and Repair Fuel Pressure Pulsation Damper: Service and Repair Fuel Pulse Dampener Replacement Removal Procedure 1. Remove the upper intake manifold. 2. Remove the fuel pressure dampener retaining clip (7). 3. Twist and pull the fuel pressure dampener (6) in order to remove the regulator from the housing using a shop towel to catch any spilled fuel. 4. Remove and discard the dampener O-ring seal (5). 5. Cover the fuel pressure dampener housing to prevent contamination from entering the fuel system. Installation Procedure 1. Lubricate the NEW O-ring with clean engine oil. 2. Install the fuel pressure dampener O-ring seal (5). Page 16965 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 13599 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 3933 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 16044 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 2940 Page 6625 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 6299 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 21611 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 15058 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8072 Vehicle Zoning Strategy Truck Zoning Page 12216 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 6601 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 4699 19. If required, remove the power brake booster vacuum fitting. 20. Remove and discard the O-ring seal. 21. If required, remove the PCV valve cover. 22. Remove and discard the O-ring seal. 23. If required, remove the rear throttle body stud. 24. Remove the throttle body. 25. Remove and discard the throttle body gasket. 26. If required, remove the MAP sensor. 27. Remove and discard the MAP sensor seal. Page 3546 For vehicles repaired under warranty, use the table. Disclaimer Page 11955 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 6923 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 2801 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 10655 Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Extended Cab) Fuel Hose/Pipes Replacement - Chassis (Extended Cab) Removal Procedure Important: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. 3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. Page 5454 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 3158 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 5990 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 8148 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 10569 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Electrical - 'No Trailer Connected' Message On DIC Trailer Brake Control Module: All Technical Service Bulletins Electrical - 'No Trailer Connected' Message On DIC TECHNICAL Bulletin No.: 09-05-22-004 Date: November 05, 2009 Subject: No "Trailer Connected" Message on Driver Information Center (DIC) at Startup When Trailer is Connected (Reprogram ITBCM) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Equipped with Integrated Trailer Brake (RPO JL1) Condition Some customers may comment that when they connect their trailer, with the engine off, and after they start the engine, the Trailer Connected message is not displayed on the DIC. With the engine running, if the trailer connector is cycled, the vehicle will detect the trailer and display Trailer Connected. This concern should only affect trailers equipped with trailer brakes on a single axle. Cause The trailer brake control system is only compatible with trailers equipped with electric trailer brakes. The system will not work or detect trailers equipped with any other types of brakes such as surge, air or electric-over-hydraulic trailer brake systems. When a trailer is connected, the Trailer Brake Control Module (TBCM) performs a test to determine if the trailer is equipped with electric trailer brakes. If the trailer wiring or electric trailer brake magnets have additional resistance (caused by poor connections, corrosion, improper splices, etc.), the TBCM may not be able to detect the trailer. Correction A revised calibration has been developed to address these issues. Reprogram the Integrated Trailer Brake Control Module (ITBCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Refer to Trailer Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10731 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 15165 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Page 2335 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 10547 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 3830 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Page 21429 Glove Compartment: Service and Repair Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Instrument Panel Compartment Door Dampener Replacement (With RPO SLT) Page 4074 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 21201 Transmission Support Crossmember Replacement (4WD 2500 HD/3500) Transmission Support Crossmember Replacement (4WD 2500 HD/3500) Testing and Inspection Fan Clutch: Testing and Inspection Fan Clutch Diagnosis Step 1 - Step 9 Page 6759 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 9266 Crankshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 14860 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Install drain pans under the vehicle as needed. Notice: Refer to Power Steering Hose Disconnected Notice. Important: Note the routing of the power steering gear inlet hose before removal. It MUST be routed correctly upon installation. 2. Remove the power steering gear inlet hose (2) from the power brake booster (1). 3. Remove the power steering gear inlet hose (2) from the power steering gear. 4. Remove the power steering gear inlet hose (2) from the vehicle. Installation Procedure Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Page 6308 View of the connector when released from the component. View of another type of Micro 64 connector. Page 23493 Ambient Light Sensor: Diagrams HVAC - Automatic HVAC Connector End Views Ambient Light/Sunload Sensor Assembly Page 5495 lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If re-installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. Notice: Refer to Fastener Notice. 2. Install the ECT sensor to the cylinder head. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 10602 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Navigation Radio - Various Noises Explained Navigation System: All Technical Service Bulletins Navigation Radio - Various Noises Explained INFORMATION Bulletin No.: 06-08-44-034E Date: February 11, 2011 Subject: Information on Noise Sources from Navigation Radio - CD/DVD Disc Accessing Noise from Radio Fan, for Cooling, Disc Accessing Noise for Navigation Operation or NAV Traffic Information Models: 2008-2011 Buick Enclave 2007-2009 Cadillac SRX 2007-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007-2009 HUMMER H2 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 06-08-44-034D (Section 08 - Body and Accessories). Some customers may comment that there are unusual fan type noises coming from the navigation radio. Additionally, the customer may comment on radio noise coming from the CD/DVD or MAP disc mechanisms when CDs/DVDs or MAP discs are present in the CD mechanisms. Some customers have mentioned that radio noise is present when the customer enters the vehicle or that the noise continues after they shut the vehicle off and open the door to leave the vehicle. This noise has been described as a fan sound or hearing a disc spinning. Source of fan sound - It is normal for the radio fan to run when the vehicle is turned on and for up to three minutes after the vehicle has been turned off and the driver's door has been opened or closed. Disc spinning sound - This is a normal operational sound. This is caused by the map disc spinning behind the tilt screen. It is a normal operation after the RKE is used to unlock the vehicle or when the driver's door has been opened. This noise will also be heard during vehicle operation and up to three minutes after the vehicle has been turned off and driver's door has been opened and closed. MAP Disc Accessing "ZIP" sound - As the Navigation Radio accesses the MAP Disc, the customer may describe frequent "zip" type noises. This noise is caused by the CD Read Lens moving across the disc to access needed data for proper MAP display. To determine if the source of the noise is from accessing the MAP Disc, remove the MAP Disc to determine if the noise continues. With the addition of the Real Time NAV Traffic Feature, the MAP CD may be accessed to a greater extent thus resulting in additional MAP Drive noise. Inform the customer about these noises. If the customer believes the noise is not normal, compare the condition to a like vehicle with identical settings to determine if there is a noticeable difference. Do not replace the radio as the described conditions are normal operating characteristics. Disclaimer SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Sensor: Customer Interest SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 6902 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 24513 Notice to Customer General Motors released this product recall in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act because a defect that relates to motor vehicle safety exists in your vehicle. It was implemented to address the potential consequences of a printed circuit board electrical short within the Heated Washer Fluid System (HWFS). The significance of this failure can vary from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. This failure can occur at any time, even when the vehicle is unattended - parked and key not in the "ON" position. Note that a resulting under hood fire could also involve other nearby vehicles or structures. Performance of this recall procedure will allow your GM dealer to eliminate these risks by permanently removing the HWFS from your vehicle. In addition to the risk of a thermal incident, including a fire, it is possible that the HWFS will become inoperative at a future time. If this occurs, it will not be repaired or replaced by GM. Note that GM does not endorse or otherwise approve the Page 12648 Page 6582 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 12181 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 1366 1 - Outside Rearview Mirror - Passenger 2 - Door Lock Switch - Passenger (AU3 -AN3/DL3) 3 Passenger Door Switch (PDS) (AN3/DL3) 4 - Door Latch Assembly - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) 6 - Speaker - Right Front 7 - Window Motor - Passenger (A31) 8 - Window Switch - Passenger (A31 -AN3/DL3) 9 - Heated Seat Switch Passenger (AN3) Driver Door (AU3 -AN3/DL3) Page 11028 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 12630 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (367A) and the 1-2 shift solenoid retainer (395). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. 4. Install the pressure control solenoid (377). Notice: Refer to Fastener Notice. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Page 6350 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6979 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 11898 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 12718 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 5995 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 8596 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 17814 For vehicles repaired under warranty, use the table. Disclaimer Page 1977 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 8269 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 10596 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 333 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 9159 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 5795 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 13402 Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 09-07-30-004C Date: 110113 A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: Page 16188 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 9001 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test Circuit/System Verification Important: On the scan tool, the powertrain relay is referred to as the EC ignition relay. 1. Ignition ON, engine OFF, command the powertrain relay ON and OFF several times using the scan tool output control function. You should either hear or feel the relay click with each command. 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate on at least one test point of each fuse. ‹› If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data list. Circuit/System Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit and ground. ‹› If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 3. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 4. Verify that a test lamp illuminates between the relay coil B+ and ground. ‹› If the test lamp does not illuminate, test the relay coil B+ circuit for a short to ground or an open/high resistance. 5. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground or an open/high resistance. If the circuits test normal Page 5963 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 11674 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 2098 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21047 6. Disconnect the rear sliding window electrical connectors from the motor/module and relays (1). 7. Remove the rear sliding window motor/module assembly from the vehicle. Installation Procedure 1. Install the rear sliding window motor/module assembly to the vehicle. 2. Connect the rear sliding window electrical connectors to the motor/module and relays (1). Notice: Refer to Fastener Notice. 3. Install the rear sliding window motor/module nuts (2). Tighten nut to 10 N.m (89 lb in). 4. Install the rear sliding window regulator and cables (2) to the motor/module. 5. Install the bolt (1) to the rear sliding window regulator and cables (2). Page 11238 Page 5800 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 21374 Carpet: Service and Repair Front Floor Panel Carpet Replacement (Crew Cab) Front Floor Panel Carpet Replacement (Crew Cab) A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 15491 11. Install the front park brake cable to the frame and press the retainer into place. 12. Connect the front park brake cable to the front to intermediate park brake cable connector. 13. Lower the vehicle. 14. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling. 15. Adjust the park brake. Refer to Park Brake Adjustment (Disc Brake) Park Brake Adjustment (Drum Brake). Page 8092 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 627 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 22466 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 6521 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 13452 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 3863 Page 1123 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 7761 Body Control Module (BCM) X3 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Shift Solenoid Valve State and Gear Ratio Page 5446 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 12856 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 10565 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 15508 Power Brake Booster Replacement (Adjustable Pedals) Power Brake Booster Replacement (Adjustable Pedals) HVAC - Automatic Air Door Actuator / Motor: Diagrams HVAC - Automatic HVAC Connector End Views Air Temperature Actuator - Left Air Temperature Actuator - Right Page 10686 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip (1) from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 19540 Television / Monitor: Diagrams Entertainment/Communication Connector End Views Video Display (U42) Page 7167 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Diagrams Fuel Gauge Sender: Diagrams Displays and Gages Connector End Views Fuel Pump and Sender Assembly - Front (Gas) Fuel Pump and Sender Assembly - Rear (Gas +LY6) Service and Repair Center Link: Service and Repair Relay Rod Replacement Tools Required J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Remove the engine shield, if equipped. 2. Remove the steering linkage shock absorber from the relay rod, if equipped. Important: Discard the idler arm nut (6) and the pitman arm nut (4). 3. Remove the steering linkage inner tie rods (3). 4. Remove the idler arm nut (6) and separate the idler arm (1) from the relay rod (5) using puller J 24319-B. 5. Remove the pitman arm nut (4) and separate the pitman arm (2) from the relay rod (5) using puller J 24319-B. 6. Remove the relay rod (5) from the vehicle. 7. Inspect the threads and seals on all steering related components. Repair or replace components as needed. Installation Procedure Page 23914 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 18433 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 12788 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. 6. Enable the SIR system. Page 11464 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 14967 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 11450 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 21906 Memory Seat Module X5 (AN3) Page 10806 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 12468 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 22470 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 1208 Page 12107 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 24668 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 4929 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 2840 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 3892 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 1148 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 7977 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12733 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Interior - Power Seat Vertical Motor Inop./Seat Sticks Seat Track: All Technical Service Bulletins Interior - Power Seat Vertical Motor Inop./Seat Sticks TECHNICAL Bulletin No.: 07-08-50-017A Date: February 22, 2008 Subject: Front Power Seat Vertical Motor Inoperative, Seat Binds or Sticks in Full Up or Down Tilt Position (Install New Stops) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Impala, Monte Carlo 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Adjuster Front Seat Power, Multi-Directional, Driver or Passenger (RPOs AG1, AG2) Supercede: This bulletin is being revised to update the information and the parts quantity. Please discard Corporate Bulletin Number 07-08-50-017 (Section 08 - Body and Accessories). Condition Some customers may comment that the front driver and/or passenger power seat up and down adjustments are inoperative. They may also comment that the seat binds or sticks when in the full up or down tilt position. Cause The cause may be the nylon stop washer (1) being compressed into the lead tilt adjuster screw when in the full up or down tilt position. Correction Install new stops using the procedure below. 1. Verify that the condition is caused by the tilt adjuster screw binding or locked into the full tilt up or down position. 2. Open the hood. 3. Connect a battery charger. Refer to Battery Charging in SI. 4. Toggle the front seat switch down (1) and up (2) with the seat unoccupied. If the seat moves up and down, then proceed to Step 5. Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Allison - Automatic Transmission Shift Cable: Adjustments Allison - Automatic Transmission Range Selector Lever Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Page 13231 12. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 13. A hidden yellow identification band indicates proper joint seating. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check. Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the front grill assembly. 2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. 3. Remove the transmission fluid cooler hose from the radiator. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the engine protection shield. Entertainment System - DVD Monitor Display Inoperative DVD Player: All Technical Service Bulletins Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Page 1482 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 1868 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 10591 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 6071 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Allison - Automatic Transmission Pressure Regulating Solenoid: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Mod Main Pressure Control Solenoid Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Diagrams Combination Switch: Diagrams Lighting Systems Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Page 3473 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Wheel Alignment Specifications (Part 1) Page 4588 11. Install the engine mount to engine mount bracket bolts. (right side shown, left side similar). Tighten the engine mount to engine mount bracket bolts to 65 N.m (48 lb ft). Page 6048 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14699 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 8602 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 4259 2. Rotate the hoist shaft counterclockwise in order to lower the spare tire to the ground. Continue to rotate the shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by rotating the hoist shaft clockwise until you hear 2 clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by rotating the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, rotate the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is NOT visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Vehicle Lifting. 6. Depress the tabs, remove the guide shaft from the hoist collar, and slide the shaft toward the bumper. 7. Remove the collar from the hoist 8. Remove the bolt. 9. Remove the hoist from the bracket. Page 10971 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 5877 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 12582 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 10477 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 6487 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 7871 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 4927 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 1162 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 10915 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 16771 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Locations Parking Brake Lever: Locations Hydraulic Brake Component Views Park Brake Assembly 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Page 9536 Page 3116 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 5050 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 3939 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2167 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 17009 Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Page 6245 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 6484 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 17146 Junction Block - Left I/P X4 Page 10836 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 5366 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 17693 1. Install the power steering fluid cooler (1) to the vehicle. Notice: Refer to Fastener Notice. 2. Install the power steering fluid cooler bolts (2). Tighten the bolts to 9 N.m (80 lb in) 3. Connect the power steering fluid cooler hose (4) to the power steering pump (1). 4. Connect the power steering fluid cooler hose (3) to the steering gear (2). 5. Clean any excess fluid from the vehicle and remove the drain pans. 6. Install the radiator grille. 7. Fill and bleed the power steering system. Page 10450 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 8294 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5821 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 6599 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 2224 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 950 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 14921 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 13605 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 24171 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14281 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Locations Alarm Module: Locations Immobilizer Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 1988 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 24543 14. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 HUMMER H2 1. Open the hood and disconnect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block in the engine compartment is located on the driver side of the vehicle near the battery. Lift the cover for access to the fuse/relay block. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. 4. Remove the two relays next to the fuse to gain access to the fuse. 5. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 6. Discard the 60 amp heated windshield washer fuse. 7. Install the two relays removed in Step 4. 8. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 9 in this section of the bulletin. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 14. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 Buick Enclave Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Page 14738 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 2404 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 5813 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 12621 Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 15373 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement (With RPO JL1 and Without JL4) Page 7227 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 3971 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 7682 Disclaimer Page 15881 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 15506 Important: On low mileage vehicles, at joint between the power brake booster housing and end cap 1, light moisture is acceptable. If fluid droplets develop, the power brake booster must be replaced. 13. Inspect the power brake booster for any leaks Important: A leak between the power steering brake booster 2 and the master cylinder is not acceptable. If a leak is present, the type of fluid must be determined. Power steering fluid indicates that the power brake booster needs to be replaced. Brake fluid indicates an issue with the brake master cylinder. 14. If the power brake booster is leaking, replace the power brake booster. Refer to Power Brake Booster Replacement (Non-Adjustable Pedals) Power Brake Booster Replacement (Adjustable Pedals). 15. If brake fluid is leaking, refer to Brake Fluid Loss for additional diagnostics. See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Brake Fluid Loss Page 14079 1. Move the control valve assembly (4) into position under the transmission case. Engage the pin (1) in the manual selector valve (2) into the slot in the detent lever (3). 2. Align control valve assembly (1) with the locating pins (2) in the transmission case. Seat the control valve assembly against the transmission case and hold the position. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch Page 7952 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 7628 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 10879 and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 6. Connect a test lamp between the relay coil B+ and the relay coil control circuit. 7. Ignition ON, command the powertrain relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the relay coil control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the relay coil control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 8. Connect a 20A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 9. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 10. If all circuits test normal, test or replace the relay. Component Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Test for 65-110 ohms of resistance between terminals 85 and 86 of the relay. ‹› If the resistance is not within the specified range, replace the relay. 3. Test for infinite resistance between following terminals: * Terminal 30 and 86 * Terminal 30 and 87 * Terminal 30 and 85 * Terminal 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 20A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm of resistance between terminals 30 and 87. ‹› If greater than the specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Relay Replacement (Within an Electrical Center) Relay Replacement (Attached to Wire Harness) * Underhood Electrical Center or Junction Block Replacement * Refer to Programming and Relearning for setup and programming. See: Testing and Inspection/Programming and Relearning Page 23886 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 4143 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Filter - A/T: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the catalytic converter. 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. Page 416 Page 10790 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 941 Page 14009 Left Side Control Valve Body Assembly Page 3519 Disclaimer Page 6185 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 7270 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 11685 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 10392 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 518 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 16298 Page 10925 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 247 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 11095 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Air Bag System - DTC B0071/B0074/B0081 Code Clearing Seat Occupant Sensor: All Technical Service Bulletins Air Bag System - DTC B0071/B0074/B0081 Code Clearing Bulletin No.: 07-09-41-004 Date: June 13, 2007 INFORMATION Subject: New Procedure for Clearing Passenger Presence System (PPS) and Sensing and Diagnostic Module (SDM) DTCs B0071, B0074, B0081 Models: 2006-2008 Buick Lucerne 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Monte Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Silverado, Suburban, Tahoe 2007-2008 GMC Yukon, Yukon Denali, Yukon XL, Yukon XL Denali A condition exists where the passenger presence system (PPS) may continue to output a fault to the sensing and diagnostic module (SDM) after the PPS has been cleared. The fault may continue to report to the SDM if the buss has not been allowed to go to sleep prior to clearing B0081 DTC in the SDM. If B0071, B0074 or B0081/0F is received, the following procedure should be followed to clear the codes. With the Ignition OFF, open and close the driver door. With a scan tool, clear PPS DTC (B0071 or B0074). While continuing to keep the doors closed, wait 60 seconds with the ignition OFF. DO NOT operate any functions in the vehicle during this time. Verify that the PPS does not have any DTCs. If PPS DTCs exist, please perform the necessary repair. With the scan tool, clear DTC B0081. Disclaimer Page 5054 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 3864 Page 9544 Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (2) up and over the knock sensor. Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 8255 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 2160 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 15589 Electronic Brake Control Module (JH6/JH7) Page 553 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 14205 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) Tools Required * J 8092 Universal Driver Handle-3/4 in - 10 * J 21128 Axle Pinion Oil Seal Installer (8.6 inch and 9.5 inch LD Axles) * J 23690 Axle Shaft Bearing Installer (8.6 inch and 9.5 inch LD Axles) * J 2619-01 Slide Hammer * J 29709 Wheel Bearing Installer (9.5 inch Axle) * J 29712 Wheel Bearing Remover (9.5 inch Axle) * J 29713 Axle Seal Installer (9.5 inch Axle) * J 44685 Rear Axle Seal and Bearing Remover (8.6 inch and 9.5 inch LD Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch and 9.5 inch LD axles) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure Air Distributor Duct Replacement Air Duct: Service and Repair Air Distributor Duct Replacement Air Distributor Duct Replacement Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: Customer Interest Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 4157 Fuse Block - Underhood X5 (Pin A1 To K3) Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 14938 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control Solenoid 1 (PCS1) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Page 482 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 444 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 18677 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Page 10929 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 9327 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 14932 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 13547 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 4241 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 23550 Page 8152 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Locations Accelerator Pedal Position Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 2685 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 6414 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 2365 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 8976 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: Customer Interest Park Assist System - Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Page 9023 Vehicle Zoning Strategy Truck Zoning Page 2643 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 10667 16. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 N.m (18 lb ft). 17. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP line. 20. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. 21. Connect the fuel feed line (1) quick connect fitting to the fuel rail. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Page 9227 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 4591 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolts. Notice: Refer to Fastener Notice. 3. Install the engine mount bracket bolts. Tighten the engine mount bracket bolts to 75 N.m (55 lb ft). 4. Position the engine mount side bracket to the engine, if removed. 5. Install the engine mount side bracket bolts. Tighten the engine mount side bracket bolts to 50 N.m (37 lb ft). 6. Install the engine mount. 7. Install the engine mount bolts. Tighten the engine mount bolts to 50 N.m (37 lb ft). 8. Lower the engine. 9. Install the starter. 10. Install the oil pan skid plate and bolts. Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft). Page 6764 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 1372 Driver Door Switch (DDS) X4 (AN3) Page 14250 2. Position the wheel stud in the rear axle hub. 3. Using washers and a wheel nut, tighten the wheel nut until the wheel stud is fully seated in the rear axle hub. 4. Remove the lug nut and the washers. 5. Lubricate the following with a light coat of high melting point EP bearing lubricant: ^ The outer wheel bearing ^ The inner wheel bearing ^ The outer wheel bearing cup ^ The inner wheel bearing cup ^ The axle hub spindle 6. Install the outer bearing into the rear axle hub. Page 6182 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Locations Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 11136 Page 7206 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 21885 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 5927 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 4022 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 5032 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 16195 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 10140 Accelerator Pedal Position Sensor: Diagrams Engine Controls Connector End Views Accelerator Pedal Position (APP) Sensor Page 16958 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Electrical - 'No Trailer Connected' Message On DIC Trailer Brake Control Module: Customer Interest Electrical - 'No Trailer Connected' Message On DIC TECHNICAL Bulletin No.: 09-05-22-004 Date: November 05, 2009 Subject: No "Trailer Connected" Message on Driver Information Center (DIC) at Startup When Trailer is Connected (Reprogram ITBCM) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Equipped with Integrated Trailer Brake (RPO JL1) Condition Some customers may comment that when they connect their trailer, with the engine off, and after they start the engine, the Trailer Connected message is not displayed on the DIC. With the engine running, if the trailer connector is cycled, the vehicle will detect the trailer and display Trailer Connected. This concern should only affect trailers equipped with trailer brakes on a single axle. Cause The trailer brake control system is only compatible with trailers equipped with electric trailer brakes. The system will not work or detect trailers equipped with any other types of brakes such as surge, air or electric-over-hydraulic trailer brake systems. When a trailer is connected, the Trailer Brake Control Module (TBCM) performs a test to determine if the trailer is equipped with electric trailer brakes. If the trailer wiring or electric trailer brake magnets have additional resistance (caused by poor connections, corrosion, improper splices, etc.), the TBCM may not be able to detect the trailer. Correction A revised calibration has been developed to address these issues. Reprogram the Integrated Trailer Brake Control Module (ITBCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Refer to Trailer Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9309 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10173 Page 7612 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 21601 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 9082 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 18226 Air Register: Service and Repair Instrument Panel Center Air Outlet Replacement (without RPO SLT) Instrument Panel Center Air Outlet Replacement (without RPO SLT) Page 24217 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 18352 Page 5828 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 10216 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 527 Page 24296 6. Disconnect the rear sliding window electrical connectors from the motor/module and relays (1). 7. Remove the rear sliding window motor/module assembly from the vehicle. Installation Procedure 1. Install the rear sliding window motor/module assembly to the vehicle. 2. Connect the rear sliding window electrical connectors to the motor/module and relays (1). Notice: Refer to Fastener Notice. 3. Install the rear sliding window motor/module nuts (2). Tighten nut to 10 N.m (89 lb in). 4. Install the rear sliding window regulator and cables (2) to the motor/module. 5. Install the bolt (1) to the rear sliding window regulator and cables (2). Page 889 Body Control Module (BCM) X7 Page 17339 Multiple Junction Connector: Diagrams X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness X103 Page 14690 Shift Interlock Solenoid: Diagrams Shift Lock Control Connector End Views A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid Page 9336 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 8689 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6567 Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 3. Remove the fuel pump/oil pressure sensor fitting, if necessary. Installation Procedure 1. If installing the old fitting, apply sealant to the threads of the fitting. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 2. Install the fitting until snug, if necessary. Notice: Refer to Fastener Notice. 3. Tighten the fuel pump/oil pressure sensor fitting. 1. Tighten the fitting to 15 N.m (11 lb ft). 2. Increase torque until the centerline of the fitting (1) is 50 degrees from the centerline of the crankshaft (2). Page 11107 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 16270 Junction Block - Left I/P X1 (Pin M2 To P5) Junction Block - Left I/P X2 Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: All Technical Service Bulletins Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 7828 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 2700 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 14544 Control Module: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (MW7) 1 - Transmission Control Module 2 - Transmission Control Module Connector 3 - Radiator Fan Shroud Page 16434 Inline Harness Connector End Views X321 Body Harness to Headliner Harness (A48) X322 Inline Harness Connector End Views X322 Body Harness to UPA Jumper Harness (UD7) Page 11916 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 12847 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 14301 26. Align the following during this procedure: * The CV joint boot (3) * The CV joint assembly (1) * The swage ring (2) 27. Install the top half of J 36652-1 or J 36652-2 onto the lower half of the tool, over the CV joint boot (3) and the CV joint assembly (1). 28. Align the swage ring (2) and the swage ring clamp. 29. Insert the bolts into J 36652-1 or J 36652-2. Hand tighten the bolts until the bolts are snug. Tighten each bolt 180 degrees at a time. Alternate between the bolts until both sides of the top half of the tool touch the bottom half of the tool. 30. Loosen the bolts and remove the halfshaft assembly from the tool. 31. Install the wheel drive shaft seal cover, if applicable. 32. Install the wheel drive shaft. Page 14469 Notice: Refer to Fastener Notice. 3. Install the flywheel bolts. Tighten the bolts in the sequence shown to 100 N.m (74 lb ft). 4. Install the automatic transmission. Page 6700 4. Connect the engine wiring harness electrical connector (2) to the HO2S pigtail electrical connector (1). 5. Install the CPA retainer. 6. Lower the vehicle. Page 10566 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 5201 Page 8131 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 15610 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 19761 Page 3991 Page 8254 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 7833 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Locations Torque Converter Clutch Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Sunroof Window Replacement (Crew Cab) Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement (Crew Cab) Sunroof Window Replacement (Crew Cab) Removal Procedure Important: The sunroof must be in the fully closed position prior to removing the sunroof window. 1. Open the sunshade panel. 2. Remove the 4 screws (2) that retain the sunroof window (1) to the sunroof module assembly. 3. Remove the sunroof window from the top of the vehicle. Installation Procedure 1. Position the sunroof window (1) to the vehicle. 2. Loosely insert the screws (2) that retain the sunroof window (1) to the sunroof module assembly. Notice: Refer to Fastener Notice. 3. Adjust the sunroof window panel as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment. Tighten the screws to 3 N.m (27 lb in). Page 24524 Scott Lawson General Director, Customer and Relationship Services Page 1268 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 12596 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 2659 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 22329 Front Seat Cushion Rear Frame Center Cover Replacement Front Seat Cushion Frame Replacement Page 11175 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 20058 Page 9321 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 9904 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 3788 3. For the 9.5/9.5LD and the 10.5 inch axles, install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 4. For the 11.5 inch axle, install the seal and the fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 5. Lower the vehicle. Page 10391 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 2163 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 11068 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 17291 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Page 18762 Page 9506 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 22405 Page 9440 Knock Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 4386 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Page 17581 Wheel Alignment Specifications (Part 2) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 16713 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 1978 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 22954 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 8749 Body Control Module (BCM) X2 Page 17899 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Page 22347 Page 10436 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 5337 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 5148 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 18380 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 22484 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Brake Master Cylinder Pressure Sensor (JL1) Brake Master Cylinder Pressure Sensor (JL1) Page 15746 18. Remove the auxiliary battery positive cable from the vehicle. Installation Procedure 1. Install the auxiliary battery positive cable to the vehicle. Page 6595 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 9645 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Body - Chrome Outside Door Handle Loose/Cracked Rear Door Exterior Handle: Customer Interest Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Page 11494 2. Place the ignition coil on top of the bracket and install the bolts. Tighten the bolts to 12 N.m (106 lb in). 3. Position the engine wiring harness branches as required. 4. Connect engine wiring harness electrical connector (7) to the ignition coil. Page 10339 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 6633 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 2834 Page 10684 4. Inspect for fuel leaks. Page 22104 Head Rest: Service and Repair Rear Seat Head Restraint Guide Replacement Rear Seat Head Restraint Guide Replacement Page 10673 4. Inspect for fuel leaks. Page 7757 Body Control Module: Locations Data Communication Component Views Behind the I/P 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) (Export) Below the I/P Page 9726 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 1913 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 11443 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 378 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 24498 the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers/retailers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information No parts are required for this recall. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Note (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by June 8, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS or GWM. Note Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Customer Reimbursement - For Saturn US Only All customer requests for reimbursement for previous repairs for the recall condition are handled by submitting a recall reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center. A Saturn Customer Reimbursement Procedure and Claim Form are included with the customer letter. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - submit as Net Item under the repair labor code. Page 5012 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 2454 Page 5743 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 11679 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 5980 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 14155 Fluid - Differential: Removal and Replacement Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (8.6 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Carefully remove the rear axle housing cover (2) and drain the lubricant into a suitable container. 5. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. 6. Inspect the bottom of the rear axle housing for excessive metal particle accumulation. This accumulation is an indication of extreme wear. Installation Procedure 1. Install a new gasket and the rear axle housing cover (2). Notice: Refer to Fastener Notice. Important: Do not reuse the rear axle housing cover bolts. Page 7559 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 12361 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 2988 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure OnStar(R) - False Crash Detection Customer Calling Emergency Contact Module: All Technical Service Bulletins OnStar(R) - False Crash Detection Customer Calling TECHNICAL Bulletin No.: 08-08-46-002 Date: June 26, 2008 Subject: OnStar(R) Calls Unwanted, False Crash Detection Customer Calling (Reprogram SDM) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with OnStar(R) (RPO UE1) Condition Some customers may comment on receiving unwanted calls from the OnStar(R) Center. Cause During certain extreme vehicle maneuvers, the vehicle SDM may mistakenly detect a crash event and generate a call to the OnStar(R) call Center. The OnStar(R) advisor is connected to the vehicle to see if everyone is alright and if a request for emergency help is needed. Correction A revised SDM Operating System software has been developed to address this issue. Reprogram the Sensing and Diagnostic Module (SDM) with the controller option described as "SDM Sensing and Diagnostic Module" under Operating System using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 13514 Shift Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 3285 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Page 6057 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 19566 3. Inspect the wiring harness for damage or improper routing near drivers side rear screw hole. Refer to the above graphic (callout # 1 shows proper routing callout # 2 indicates improper routing). 4. Repair the wiring harness as necessary. If the wiring harness is not damaged refer to SI for diagnosis and repair of the system. 5. Install the DVD screen and the four retaining screws. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2144 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 9274 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 14122 6. Lower the transmission sufficiently to provide access to the engine wiring harness where it routes from the engine intake manifold to the transmission bell housing as shown. 7. Release the wiring harness conduit from the retainers that secure it to the transmission and/or transfer case. Note IT WILL be necessary to extract the wiring harness from the protective conduit if chafing IS NOT observed on exposed wiring. 8. Examine the harness for wiring that may be exposed outside of the conduit. Inspect ALL areas for chafing as shown. If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 9. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 10. Raise the transmission as needed to install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. 11. Lower the vehicle. 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 13. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Engine Intake Manifold 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. Page 7766 Body Control Module (BCM) X7 Page 2117 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 1766 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Notice: Refer to Fastener Notice. 2. Install the accelerator pedal bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: Page 15024 12. Inspect the transmission fluid pressure manual valve position switch assembly for the following conditions: * Damage * Debris * Damaged or missing O-rings * Cracked connector * Loose electrical terminals * Poor terminal retention 13. Remove the manual detent spring bolt. 14. Remove the manual detent spring. 15. Inspect the manual detent spring for cracks or damage. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 16. Remove the remaining valve body bolts. Page 1875 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 2392 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 7921 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 4260 10. Remove the spare tire hoist shaft guide from the bumper. Installation Procedure 1. Install the spare tire hoist shaft guide to the bumper. 2. Install the hoist to the crossmember. Notice: Refer to Fastener Notice. 3. Install the bolt. Tighten the bolt to 40 N.m (30 lb ft). 4. Install the collar to the hoist 5. Install the shaft to the hoist. Page 21821 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 16047 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 7262 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 14200 Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Notice: Refer to Fastener Notice. 4. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence to 165 N.m (122 lb ft). 5. Install the pinion and the pinion bearings. 6. Install the pinion gear bearing retainer. 7. Install the differential assembly. 8. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 9. Lower the vehicle. Page 9784 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 2064 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 20990 Page 15798 Ignition Lock: Service and Repair Ignition Lock Cylinder Replacement Ignition Lock Cylinder Replacement Removal Procedure Caution: Refer to SIR Caution. 1. Disable the SIR system. Refer to SIR Disabling and Enabling. 2. Remove the knee bolster. 3. Remove the steering column shroud. 4. With the key installed hold it in the START position. 5. Install an allen wrench into the hole on top of the ignition lock cylinder case. Push down on the allen wrench to release the tab on the ignition lock cylinder inside the ignition lock cylinder case. 6. Slide the ignition lock cylinder out of the ignition lock cylinder case. Installation Procedure Important: The gears between the ignition/start switch and the ignition lock cylinder case must be in the correct position. Failure to do so will cause a misalignment of the gears in the ignition/start switch and the ignition lock cylinder case, which may result in a NO START or BATTERY DRAIN. 1. Use a screwdriver to rotate the ignition lock cylinder case gear clockwise to the start position allowing it to spring return into the RUN position. Page 23300 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 14861 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Lighting - Brake Lamps Turn Off After Stop/Pedal Applied Brake Light Switch: All Technical Service Bulletins Lighting - Brake Lamps Turn Off After Stop/Pedal Applied TECHNICAL Bulletin No.: 08-08-42-003A Date: August 14, 2009 Subject: Stop Lamps Intermittently Turn Off After Coming to a Complete Stop While Still Having Pressure on Brake Pedal (Replace Stop Lamp Switch) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to provide a new part number. Please discard Corporate Bulletin Number 08-08-42-003 (Section 08 - Body & Accessories). Condition Some customers may comment on the stop lamps turning off prior to the brake pedal reaching the fully released position. Some customers may also comment on the stop lamps turning off while having light pressure on the brake pedal. Some customers with Integrated Trailer Brake Control (ITBC) may comment that the electronic trailer brakes disengage after the vehicle has come to a complete stop. This disengaging of the trailer brakes coincides with the stop lamps turning off. Cause This condition may be caused by not enough pressure being applied to the stop lamp switch to keep the brake lights on. Correction Technicians are to replace the stop lamp switch. The new stop lamp switch has a reduced internal spring apply force, which will allow the lamps to stay on with less applied brake force. 1. Refer to SI for Stop Lamp Switch replacement procedures. 2. Use the new Stop Lamp Switch, P/N 25981009. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 17356 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness Page 3310 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 12861 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 10081 2. Slide the EVAP canister vent solenoid onto the bracket towards the rear of the vehicle. 3. Ensure that the retainer (1) is engaged, securing the EVAP canister vent solenoid. 4. Connect the EVAP vent solenoid pipe quick connect fitting (3) to the EVAP canister. 5. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid. 6. Install EVAP canister vent solenoid clip (1) to the chassis EVAP line. 7. Install the EVAP canister vent solenoid pipe to the clip (2) on the chassis EVAP line. 8. Install the EVAP canister vent solenoid pipe to the clips (3) on the brake pipes. 9. Lower the vehicle. Page 8112 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 16049 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 10476 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 4685 4. Remove the bolts and the nut for the P/S pump bracket. 5. Leave the A/C compressor, if equipped, and the P/S pump on the bracket. 6. Slide the P/S pump bracket forward to access the front intake manifold bolt. 26. Remove the intake manifold - lower bolts. 27. Remove the intake manifold. 28. Remove and discard the intake manifold gaskets. 29. Clean and inspect the intake manifold - lower, if necessary. Refer to Intake Manifold Cleaning and Inspection. Installation Procedure Notice: Apply the proper amount of the sealant when assembling this component. Excessive use of the sealant can prohibit the component from sealing properly. A component that is not sealed properly can leak leading to extensive engine damage. 1. Apply a 4.0 mm (0.157 in) patch of adhesive to the cylinder head side of the intake manifold gasket at each end. Refer to Sealers, Adhesives, and Lubricants for the correct part number. Important: The intake manifold gasket must be installed while the adhesive is still wet to the touch. 2. Install the intake manifold gasket onto the cylinder head. Use the gasket locating pins in order to properly seat the gasket. Page 19208 Disclaimer Page 12255 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 6925 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 8924 View of the connector when released from the component. View of another type of Micro 64 connector. Page 4680 8. Reposition the heater inlet and outlet hoses. 9. Disconnect the engine wiring harness electrical connector (2) from the throttle body. 10. Disconnect the following electrical connectors: * The A/C pressure switch (1), if equipped * The air conditioning (A/C) compressor clutch (2), if equipped TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Diagrams Oil Pressure Sender: Diagrams Displays and Gages Connector End Views Engine Oil Pressure (EOP) Sensor (Gas) Page 10671 1. Install the following NEW components to the fuel meter body: * Lower fuel seal (4) * Spacer ring (3) * Upper fuel seal (2) * Fuel seal retainer (1) Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Apply a few drops of clean engine oil to the fuel pipe end. 3. Install the fuel pipe to the fuel meter body. 4. Install the fuel pipe retainer. Page 4566 Step 1 - Step 7 Page 12720 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 7597 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 422 Vehicle Zoning Strategy Truck Zoning Page 3981 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 10859 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Engine Controls - Cruise Control Turns Off When Operated PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11242 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Mount: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Mount Replacement (2WD) Page 14820 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. Tighten the bolts to 12 N.m (108 lb in). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Page 9193 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13585 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 2337 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Service and Repair Antenna, Phone: Service and Repair Mobile Telephone Digital Antenna Replacement Page 5002 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2071 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 9570 Page 10292 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Page 15930 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9820 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 14918 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 15906 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 16186 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 8405 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Trailer Hitch Replacement (Light Duty) Trailer Hitch: Service and Repair Trailer Hitch Replacement (Light Duty) Trailer Hitch Replacement (Light Duty) Removal Procedure 1. Disconnect the trailer wiring harness connector (3) from the trailer wiring recepticle (4). 2. Remove the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 3. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 4. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 5. Remove the hitch platform bolts (6) from the frame weld nuts (2). 6. Remove the hitch platform from the vehicle. Installation Procedure Procedures Brake Rotor/Disc: Procedures Brake Rotor Refinishing Tools Required * J 41013 Rotor Resurfacing Kit * J 42450-A Wheel Hub Resurfacing Kit Caution: Refer to Brake Dust Caution. Important: * The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not refinish disc brake rotors in an attempt to correct the following conditions: - Brake system noise - squeal, growl, groan - Uneven and/or premature disc brake pad wear - Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface - Scoring of the disc brake rotor friction surface less than the maximum allowable specification * Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement. See: Testing and Inspection/Brake Rotor Thickness Measurement Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: - Thickness variation in excess of the maximum allowable specification - Excessive corrosion/rust and/or pitting - Cracks and/or heat spots - Excessive blueing discoloration - Scoring of the disc brake rotor surface in excess of the maximum allowable specification * Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification. Important: If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling. This setup requires less cutting pressure, which will result in less vibration, and a better surface finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following instructions. Important: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement. See: Testing and Inspection/Brake Rotor Thickness Measurement 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. Page 8383 Page 18268 Blower Motor: Service and Repair Blower Motor Replacement Removal Procedure 1. If equipped, remove the sound insulator panel. 2. Remove the blower motor insulating cover screws. 3. Disconnect the electrical connector from the blower motor. 4. Remove the blower motor insulating cover. 5. Pull the retaining tab down while turning the blower motor counterclockwise in order to disengage the blower motor from the heater/ventilation module. 6. Remove the blower motor. Installation Procedure 1. Install the blower motor. OnStar(R) - Language Change Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Page 12815 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 21616 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 2645 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 1867 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Windshield Wiper Arm Replacement (LD) Wiper Arm: Service and Repair Windshield Wiper Arm Replacement (LD) Windshield Wiper Arm Replacement (LD) Page 23928 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12543 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 10995 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 7046 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 4126 Junction Block - Left I/P X2 (Pin E3 To P5) Junction Block - Left I/P X3 Body - Door Module/Switch Programming Information Door Module: Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Page 9874 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 5185 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 3029 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 16225 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: All Technical Service Bulletins A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Page 10411 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 8109 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 24678 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 2517 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 5824 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 20576 Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar End Cap Replacement Rear Bumper Impact Bar End Cap Replacement Page 16293 Fuse Block - Underhood X1 Page 8574 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 1901 Camshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 11595 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 13724 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Page 20932 Page 15585 Electronic Brake Control Module (JL4) Page 9499 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 16613 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 14734 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 7302 4. Connect the engine wiring harness electrical connector (4) to the CKP sensor. 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. 7. Perform the crankshaft position system variation learn procedure. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 7349 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 6673 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 6815 Transmission Position Switch/Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 629 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Lighting - Turn Signals Have Increased Flash Rate Body Control Module: Customer Interest Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12265 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 11271 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 11332 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Front Wheel Speed Sensor Replacement (JD9, JF3, JF7) Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement (JD9, JF3, JF7) Front Wheel Speed Sensor Replacement (JD9, JF3, JF7) Page 119 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 19582 Entertainment System Control Module: Service and Repair Audio System Transceiver Module Replacement Page 5308 View of the connector when released from the component. View of another type of Micro 64 connector. Page 12198 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 22835 3. Install the weatherstrip (1) to the pinch-weld flange (2). Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Refer to Front Side Door Sill Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Plate Replacement (Extended Cab) or Rear Side Door Sill Plate Replacement (Extended Cab) Rear Side Door Sill Plate Replacement (Crew Cab) . Page 7351 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 10577 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 9972 9. Remove the left rear CPA retainer. 10. Disconnect the engine wiring harness electrical connector (1) from the left rear HO2S electrical connector (2). 11. Remove the left rear HO2S electrical connector clip from the frame. 12. For vehicles equipped with 2 wheel drive (2WD) perform the following steps, for vehicles equipped with 4 wheel drive (4WD) proceed to step 15. 13. Remove the left front CPA retainer. 14. Disconnect the left front HO2S electrical connector (7) from the engine wiring harness electrical connector (6). Page 2271 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 21607 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 10792 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 300 Power Seat Control Module: Diagrams Power Seat Connector End Views Memory Seat Module X1 (AN3) Memory Seat Module X2 (AN3) Page 7265 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 11587 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 20008 Warranty Information (Saab U.S. Models) Disclaimer Page 12906 Shift Solenoid 1 (SS1) Shift Solenoid 2 (SS2) Page 16642 The IP wiring branch to C202 (IP to body cam lock connection) may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been seated. Possible point of contact (2). The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been seated. Possible points of contact (1, 2). The IP wiring branch to C202 may have never been secured into place (gray retaining clip (1) off the branch was never seated). Page 976 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 14335 3. Install the outer bearing cup into the wheel hub. 4. Drive the outer bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Turn the wheel hub over and seat the outer bearing assembly against the retaining ring using the J 24426 (2) and the J 8092 (1). 7. Ensure that the outer bearing assembly rotates freely in the hub. Page 16901 Page 11409 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 7587 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 18416 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Exhaust System - Moan/Vibration Noise At Low RPM Exhaust Pipe/Muffler Hanger: Customer Interest Exhaust System - Moan/Vibration Noise At Low RPM TECHNICAL Bulletin No.: 02-06-05-003J Date: February 16, 2011 Subject: Exhaust Moan/Vibration Noise (Install Exhaust System Flex Pipe Kit) Models: 1999-2007 Chevrolet Silverado 1500 Series Extended Cab or Regular Cab/Long or Short Box Pickups (Classic) 2007-2011 Chevrolet Silverado 1500 Series Extended Cab or Regular Cab/Long or Short/Standard Box Pickups (New Body Style) 1999-2007 GMC Sierra 1500 Series Extended Cab or Regular Cab/Long or Short Box Pickups (Classic) 2007-2011 GMC Sierra 1500 Series Extended Cab or Regular Cab/Long or Short/Standard Box Pickups (New Body Style) Equipped with 4.3L Engine (VINs W, X - RPOs L35, LU3) and Automatic Transmission (RPO M30) New Body Style 2007-2011 Fort Wayne (VIN Z - RPO FWI) Built Vehicles Before January 2011 and All Silao (VIN G - RPO MSL) Built Vehicles Supercede: This bulletin is being revised to add the 2011 model year and vehicle build information. Please discard Corporate Bulletin Number 02-06-05-003I (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a moan or vibration noise at low vehicle speeds 40-64 km (25-40 mph) or between 900-1700 RPM under load. Cause Exhaust system resonance may be transmitted through the powertrain mounts into the body causing this condition. Correction Caution Personal injury or burns may occur when working on a hot exhaust system, let the exhaust system cool off prior to performing the repair. An exhaust system flex pipe kit is available to correct this condition. If diagnosis leads to this condition, install the applicable exhaust system flex pipe kit listed below using the following procedure. Refer to the Parts Information for kit applications and usage. Important This fix and the kit part numbers are specific to vehicle frame type. A Level 3 frame was introduced interim 2000 model year (approximately January 2000). With a Level 3 frame, the transmission crossmember was moved forward of its previous location. Pre-Level 3 frames will require the installation of additional components to correct the condition. 1999-2000 4WD Models Built Prior to 1/20/2000 and All 2000-2011 2WD and 4WD Models Built After 1/2000 (Fort Wayne Built Vehicles Before 1/2011 and All Silao Built Vehicles) (Except Regular Cab Short Bed Vehicles) These models require the installation of a flex coupling. The flex coupling has adapter sleeves for the installation of U-bolt clamps. This procedure uses the U-bolt clamps, but the preferred installation method is to weld the flex coupler to the exhaust pipe. 1. Raise the vehicle. 2. Locate the first available straight section of pipe rearward of the mid-joint flange and forward of the muffler assembly. 3. Measure approximately 228 mm (9 in) on the straight pipe and mark. 4. Using a suitable cutting tool, cut out the marked section of the pipe and remove. 5. Remove any burrs, if necessary, before installing the flex coupler pipe. Page 11785 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 1812 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 9797 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 23624 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 14774 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 22759 For vehicles repaired under warranty, use the table. Disclaimer Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Disconnect the engine wiring harness electrical connector (4) from the crankshaft position (CKP) sensor. Page 15471 1. Connect the left park brake cable eye (1) to the park brake actuator lever (2). 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (3) rearward to compress the spring and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Notice: Refer to Fastener Notice. 3. Install the park brake cable clip bolt. Tighten the bolt to 22 N.m (16 lb ft). Page 8643 Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (4). Tighten the sensor to 42 N.m (31 lb ft). 3. Install the HO2S pigtail electrical connector clip (2) to the frame. Page 13738 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 6318 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21796 Vehicle Zoning Strategy Truck Zoning Page 12244 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3962 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 19899 Disclaimer Page 1855 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 20402 Disclaimer Page 17034 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 8237 Page 8472 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 20376 Trailer Brake Control Module: Service and Repair Trailer Brake Control Relay Replacement Trailer Brake Control Relay Replacement Page 11813 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4014 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 17587 Alignment: Description and Operation Caster Description Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Page 3924 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 9103 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 9975 1. If replacing the catalytic converter assembly, perform the following steps, otherwise proceed to step 4. 2. If reinstalling the old sensors, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Component Fastener Tightening Notice. 3. Install the HO2S (1-4) to the catalytic converter assembly. Notice: Refer to Fastener Notice. Tighten the sensors to 42 N.m (31 lb ft). 4. Install the NEW exhaust seals (2 and 3) as required. 5. Install the catalytic converter assembly to the muffler. 6. Install the catalytic converter assembly to the exhaust manifolds. 7. Install the catalytic converter to exhaust manifold nuts (1). Tighten the nuts to 50 N.m (37 lb ft). Page 2457 Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 4047 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Body - Tubular Assist Step Service Parts Cpomponents Auxiliary Step / Running Board: Technical Service Bulletins Body - Tubular Assist Step Service Parts Cpomponents INFORMATION Bulletin No.: 09-08-61-001A Date: October 21, 2009 Subject: Information on Tubular Assist Step Service Part Component Availability Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to add the 3" round service components. Please discard Corporate Bulletin Number 09-08-61-001 (Section 08 - Body and Accessories). Service Component Availability Some dealers have submitted warranty claims against and replaced entire tubular assist step packages for customer concerns that only require the replacement of a serviced component. Dealers may not have been aware that the components of the tubular assist step packages, such as brackets, end caps, step pads and mounting hardware are available as service parts. This information is in the chart below. Instructions If the condition can be corrected with a component replacement instead of replacing the tubular assist step packages, order the component only. Use the attached parts information to order the components. The parts are in Group 21.506B in the Service Parts Catalog. Page 19383 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Important: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems. 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gages. Page 607 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 7421 Page 14564 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Restraint System - Normal Safety Belt Locking Conditions Seat Belt: All Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Page 9100 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12087 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 21914 Power Door Lock Relay: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 6526 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 8967 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 10459 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 3117 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 13676 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Page 8448 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 6197 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 7098 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 7983 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 22514 ‹› If the MSM parameters are not displayed correctly replace the MSM. 3. If the circuits test normal replace the driver or passenger door module. Component Testing 1. Disconnect the heated seat switch connector at the door module. 2. Connect a fused jumper wire from the low reference circuit terminal 4 to ground. 3. Verify that a test lamp does not illuminate when connected from battery voltage to the switch signal circuit terminals 6 and 7. ‹› If the test lamp illuminates while the switches are in an inactive state, replace the heated seat switch. 4. Verify that a test lamp illuminates when connected from battery voltage to the switch signal circuit terminals 6 and 7 while pressing the heated seat switches. ‹› If the test lamp does not illuminate while the switches are in an active state, replace the heated seat switch. 5. Verify that the heated seat switch indicators illuminate with a test lamp connected from battery voltage to the indicator control circuit terminals 1, 2, 9, 10, and 11. ‹› If the indicators do not illuminate replace the heated seat switch. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. * Front Seat Heater Switch Replacement (w/o KB6) * Control Module References for MSM and Driver or Passenger Door switch replacement, programming, and setup. Page 11985 Adjustments Rear Door Striker: Adjustments Door Lock Striker Adjustment To determine if striker adjustment is required, proceed as follows: 1. Make certain the door is properly aligned within the door opening before proceeding with the striker adjustment. 2. Close the door onto the striker and note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note the closing effort to fully engage the latch. 3. Using a soft marker, mark around the striker for reference of the original position. Loosen the striker. 4. Move the striker to eliminate drag on the striker and door latch and to achieve the proper door position within the door opening. Start with the up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for the proper door seal engagement making sure the door closing efforts are correct. Notice: Refer to Fastener Notice. 5. Tighten the striker-to-body bolts. Tighten the door striker-to-body bolts to 27 N.m (20 lb ft). Page 16286 Junction Block - Right I/P X4 Page 9449 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 9679 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice Heated Oxygen Sensor Resistance Learn Reset Notice Notice: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 2676 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 2030 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 5923 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 10891 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 16748 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 16908 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 12744 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 14078 9. Lower the control valve assembly (1) to clear the locating pins (2) in the transmission case. 10. Move the control valve assembly (4) sideways to disengage pin (1) in the manual selector valve (2) from the slot in detent lever (3). Remove the control valve assembly (4). Installation Procedure Page 6928 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 4034 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 16865 Disclaimer Page 13407 Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 6145 Page 22392 For vehicles repaired under warranty, use the table. Disclaimer Page 15105 Transmission Speed Sensor: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Input and Output Speed Sensor (ISS/OSS) Page 23577 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 22873 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Diagrams Ignition Relay: Diagrams Engine Electrical Connector End Views Run Relay (TP2) Run Relay (TP2) Page 14793 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 17878 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Page 1014 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 11626 5. Remove the knock sensor bolt and sensor. Installation Procedure Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). Page 1169 Page 17041 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 36 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 11738 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 11390 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Roof Beacon Relays Hazard Flasher Relay: Diagrams Roof Beacon Relays Power and Grounding Connector End Views Roof Beacon Relay (TRW) Page 5363 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 16941 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 8372 * GMLAN Wiring Repairs * Control Module References for module replacement, setup, and programming See: Testing and Inspection/Programming and Relearning Page 21822 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Diagrams Security Lamp/Indicator: Diagrams Theft Deterrent System Connector End Views Security Indicator Lamp (SPO Alarm) Page 17142 Junction Block - Left I/P X1 (Pin A1 To M1) Page 3439 Page 17046 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 23061 Page 6129 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 15768 Battery Current Sensor: Diagrams Battery Current Sensor (10 Series) Battery Current Sensor (10 Series) Page 13540 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Service and Repair Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Page 8006 Crankshaft Position Sensor: Connector Views Engine Controls Connector End Views Crankshaft Position (CKP) Sensor Page 23900 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 6246 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Temperature Versus Resistance Page 2232 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 4628 Notice: Refer to Fastener Notice. 1. If equipped with RPO LY6 (6.0L) engine, perform the following: 1. Install the oil cooler hose assembly and a NEW gasket. 2. Install the oil cooler hose adapter bolts (2). Tighten the bolts to 12 N.m (106 lb in). 3. Install the oil cooler hose bracket bolt. Tighten the bolt to 25 N.m (18 lb ft). 2. If equipped with a RPO L76 (6.0L) engine, perform the following. 1. Install the oil cooler hose assembly and a NEW gasket. 2. Install the oil cooler hose adapter bolts (2). Page 21060 2. Install the cable ends (1) to the window guide (2) at each end of the window. Important: When installing the regulator (2) align the gear to the motor drivegear before installing the screw. 3. Install the regulator (2) to the motor/module. 4. Install the screw (1) to the motor/module. Tighten nuts to 5 N.m (44 lb in). Page 2569 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 20911 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverage Adjustments are displayed in the Applicable Warranties section. Parts Information Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Replace door handle levers if signs of peeling are present. Note The handle kit contains two door handle levers, replace both sides. Front Side Door Inside Handle Replacement 1. Remove the driver and passenger front side door inside handles. Refer to Front Side Door Inside Handle Replacement in SI. 2. Place front door inside handles on a work bench. Page 9191 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 17333 X325 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) Page 12615 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 5382 Page 23623 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 10363 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 7637 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 9599 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 11615 Page 10710 1. Remove the cap from the opening on the fuel tank. 2. Position the fuel tank fill pipe. Notice: Refer to Fastener Notice. 3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 N.m (22 lb in). 4. Connect the fuel fill pipe recirculation line quick connect fitting (2) to the EVAP rear hose. 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. Page 11702 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 21395 Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Front Floor Console Compartment Door Latch Replacement (Except Cadillac) Page 11375 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 24636 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 6668 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9043 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 8604 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. OnStar(R) - Language Change Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Page 257 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 17540 The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. When releasing the park brake pedal with the park brake release lever/handle, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. Correction If the symptoms match those listed above, or if a condition is found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202), then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: Visually inspect the IP harness for damage at the park brake pedal assembly (refer to potential damage points in photos - at the side and rear of the park brake assembly). Note that damage may be hidden from view (turned away from you, or covered by electrical tape). Operate the park brake release lever. Is the moving part at the end of the park brake release cable coming into contact and damaging the IP harness? Inspect the IP harness at this point. Note that the damage may be hidden from view (by electrical tape). If damage is found, repair the wiring. Page 10519 3. Install the fuel pressure dampener (6). 4. Install the fuel pressure dampener retaining clip (7). 5. Install the upper intake manifold. 6. Tighten the fuel fill cap. 7. Connect the negative battery cable. 8. Inspect for leaks. 1. Turn the ignition ON, for 2 seconds. 2. Turn the ignition OFF, for 10 seconds. 3. Turn the ignition ON. 4. Inspect for fuel leaks. Page 4950 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 2211 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 684 Disclaimer Page 12637 Shift Solenoid: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Page 6888 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 7169 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 23012 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 587 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3295 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Page 12822 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 11066 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 20620 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Page 11988 Knock Sensor: Description and Operation Knock Sensor (KS) System Description Purpose The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor (KS) system uses one or 2 flat response 2-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the control module through a low reference circuit. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Page 16201 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 17379 X309 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) Page 5307 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 21160 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 5220 4. Connect the electrical connectors to the cooling fans. 5. Install the clip attaching the wiring harness to the shroud. 6. Install the transmission cooling line bolts to fan shroud. Tighten the bolts to 4 N.m (35 lb in). 7. If necessary, install the surge tank inlet hose to the radiator. 8. If necessary, reposition the surge tank inlet hose clamp at the radiator. Page 23610 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Campaign - BCM Reprogramming for Battery Drain Body Control Module: Recalls Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 13560 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 21328 Disclaimer Page 4127 Junction Block - Left I/P X4 Page 8396 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 18091 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 4110 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 1641 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 24439 2. Install the cable ends (1) to the window guide (2) at each end of the window. Important: When installing the regulator (2) align the gear to the motor drivegear before installing the screw. 3. Install the regulator (2) to the motor/module. 4. Install the screw (1) to the motor/module. Tighten nuts to 5 N.m (44 lb in). Page 5798 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 7288 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 11921 View of the connector when released from the component. View of another type of Micro 64 connector. Page 16446 X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness (JL4) Page 11179 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 19643 - 15882767 - 15940102 - 15940103 - 25797978 - 25834072 Update the Navigation Radio's software to correct this condition. This software upgrade will also update some operating characteristics on the Navigation Radio. The following functions or displays may be affected: Important Inform the customer that stored destinations and radio presets may not be retained during programming. - Clock font size - Text color on light colored screens - Split screen icon to minimize the "Points of Interest" popup and "Exit" popup - Destination keyboard characters moved from page 2 to page 1. - "Back" button on street address entry screen for entering street number - User selectable lock-outs for XM Categories, music Navigator, MP3 folders, address book, POI's and Turn list. - "I Agree" screen changed from every ignition cycle to once in every 50 ignition cycles. - Screen Brightness adjustment not disabled while vehicle is in motion. How to Obtain Nav Software Update Disc (P/N 25956121 - software version 0B92): Software discs are available through the GM Nav Disc Center. Dealers should treat the disc like a special tool and retain the disc for use in repairing future vehicles. DO NOT give the software disc to the customer. Navigation Software Update Procedure: Use the following procedure to update the Navigation Radio software using the Nav Software Update Disc P/N 25956121 (software version 0B92): Important - This software update can only be used to update the navigation radios specified in this bulletin. DO NOT use this software to update any other vehicle's navigation radio. - The Map DVD will be needed to verify the system operation after the software update has been performed. Use the vehicle's existing map DVD. - It is recommended to wear latex gloves while performing the software update, to avoid fingerprints on the product and discs. The software update requires using the map DVD slot. The update will not work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Notice DO NOT stop the engine until all tasks are completed. The software update MUST be performed with the engine RUNNING and the gear position in PARK. If the vehicle is turned off prior to the software update being completed, the process may not work again and a new Navigation Radio may be required. 1. Start the engine with the gear selector in PARK. Wait until the audio or caution screen is displayed after the opening screen. 2. Press the "NAV" hard key. 3. Press "OK" soft key. 4. Press the "MENU" hard key. 5. Press the "NAV" soft key. 6. Press the "MAP DATABASE INFORMATION" soft key. 7. Press the "CHANGE" soft key. Page 7272 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 13008 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 18075 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 22033 Disclaimer Page 11605 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 21516 Center Pillar Upper Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Page 20727 Front Door Panel: Service and Repair Front Side Door Water Deflector Replacement Front Side Door Water Deflector Replacement Page 20427 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 12743 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 14223 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3- 5 lb in) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts. Tighten the propeller shaft yoke retaining clamp bolts to 25 N.m (18 lb ft). 12. Install the axle shafts (10.5 inch, 11.5 inch axle). 13. Install the brake rotors (8.6 inch, 9.5 inch axles). 14. Install the brake calipers (8.6 inch, 9.5 inch axles). 15. Install the tire and wheel assemblies. 16. Inspect and add axle lubricant to the axle housing, if necessary. 17. Lower the vehicle. Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle w/Drum Brakes) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle w/Drum Brakes) Tools Required * J 8614-01 Flange/Pulley Holding Tool * J 22388 Rear Axle Pinion Oil Seal Installer - Rear Removal Procedure Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. Page 10432 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 5762 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 10553 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 20304 Page 4688 18. Install the radiator inlet hose to the thermostat housing. 19. Position the radiator inlet hose clamps. 20. Connect the power brake booster vacuum hose to the vacuum fitting. 21. Install the PCV valve hose to the valve cover and rocker cover. 22. Position the engine wiring harness and bracket. 23. Install the engine wiring harness bracket stud (1). Tighten the stud to 25 N.m (18 lb ft). 24. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve. Tighten the nut to 9 N.m (80 lb in). Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: All Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Page 2588 Accelerator Pedal Position Sensor: Diagrams Engine Controls Connector End Views Accelerator Pedal Position (APP) Sensor Page 22190 Seat Back: Service and Repair Front Seat Back Cushion Cover and Cushion Pad Replacement Front Seat Back Cushion Cover and Cushion Pad Replacement Air Temperature Sensor Replacement - Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Left Side Air Temperature Sensor Replacement - Lower Left Side Page 23952 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 23616 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 8013 Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face the engine front cover. Failure to do so will damage the front cover and the reluctor ring. 1. Install the CKP sensor reluctor ring. 1. Align the keyway on the CKP sensor reluctor ring with the key in the crankshaft. 2. Using J 5590, push the CKP sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. 2. Install the engine front cover. Page 22009 4. Connect the front sunroof drain hose to the sunroof module front spigot, right or left side, as needed. 5. Install the instrument panel trim. 6. Install the headliner. A/T Controls - DTC P1825/P182E or P1915/MIL ON PROM - Programmable Read Only Memory: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 13121 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. * Tighten the control valve body bolts to 11 N.m (97 lb in). * Tighten the TCC solenoid bolts to 11 N.m (97 lb in). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. Page 12699 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 11283 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 8277 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 14128 Important Use ONLY a clean nylon brush that is DEDICATED to the repair of this specific condition. With a one-inch nylon bristle brush, apply dielectric lubricant P/N 12377900 (in Canada, 10953529 to both the module/component side and the harness side of the affected connector(s). 3. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 4. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Page 21169 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 14129 Wiring Harness: Service and Repair Wiring Harness Replacement Tools Required * J 44247 Internal Wiring Harness Installer * J 44257 Main Wiring Harness Connector Remover Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the external wiring harness from the main transmission connector. Use J 44257, if connector is not easily accessible. Important: The main transmission connector is actually one end of the internal wiring harness that protrudes through the transmission case. 3. Place a 30 mm or 1 3/16 inch 12-point deep socket or box-end wrench (2) over the main transmission connector (1). 4. Push inward on the socket or wrench to release the retaining feet that attach the connector (1) to the transmission case. 5. Remove the wrench. Push inward on the electrical connector to separate from the transmission case. 6. Disconnect the internal wiring harness connectors (1) from the solenoids, the internal mode switch (IMS), and from the transmission fluid pressure (TFP) switch. Important: The solenoid retainers for shift solenoid 3 (SS3) and shift solenoid 2 (SS2) also retain tabs on the wiring harness U-channel. The solenoids will remain in position even after the solenoid retainers are removed. 7. Remove the solenoid retainers (2) for SS3 and SS2. 8. Remove the internal wiring harness from the transmission. Page 18690 If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Director, Customer and Relationship Services Page 2556 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6093 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 7604 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 22816 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Service and Repair Steering Damper: Service and Repair Steering Linkage Shock Absorber Replacement Tools Required J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure 1. Remove the engine shield, if equipped. Important: Discard the steering linkage shock absorber nut. 2. Remove the steering linkage shock absorber nut (1) from the steering linkage shock absorber (2). 3. Remove the steering linkage shock absorber from the relay rod using puller J 24319-B. Page 23220 * Park Tilt Mirrors * Smart High Beams Average Fuel Economy Average fuel economy is calculated using the equation: AFE = Distance/Fuel * Distance = The accumulated distance travelled since the last reset of this value * Fuel = The accumulated fuel consumption since the last reset of this value The engine control module (ECM) sends the average fuel economy GMLAN message to the instrument panel cluster (IPC). The value of this mode is retained during ignition OFF and can be changed between English units and metric units by selecting from the driver information center (DIC) options menu. Average Speed Average speed is calculated using the equation: Average Speed = AVS Distance/AVS Time * Distance = The accumulated distance travelled since the last reset of this value * Ignition On = The accumulated ignition on time since the last reset of this value Oil Life Remaining The ECM sends the oil life remaining percentage to the IPC via GMLAN message. The instrument panel cluster receives a GMLAN message indicating the engine oil life remaining. The DIC displays the current percentage of the GM Oil Life System as determined by the ECM. When the oil life remaining percentage drops below 5 percent, the DIC displays CHANGE ENGINE OIL SOON. When the engine oil is changed, reset the GM Oil Life System. Refer to GM Oil Life System Resetting. Fuel Range This message indicates the estimated distance that the vehicle can travel under the current fuel economy and fuel level conditions since the last battery connection to the IPC. Fuel Range is calculated using the equation: Fuel Range = Range Distance/Range Fuel Used. * Range Distance = The accumulated distance travelled since the last reset of this value. * Fuel Used = The accumulated fuel delivered since the last reset of this value The ECM sends the fuel range value to the IPC. The IPC receives a GMLAN message with fuel information. The fuel range value is retained during ignition OFF and can be changed between English and Metric units by accessing the DIC English/Metric menu. The Fuel Range display cannot be reset. LOW is displayed when fuel range is below a predetermined value. Fuel Used The DIC calculates and displays the total amount of fuel used since the last reset operation. You can reset the fuel used mode by depressing and holding the Set/Reset button for more than 3 seconds. The value of this mode is retained during ignition OFF. Instantaneous Fuel Economy (IFE) Instantaneous fuel economy (IFE) is calculated using the equation: IFE = Distance/Fuel Used. * Distance = The accumulated distance travelled for the last 2 seconds * Fuel = The accumulated fuel delivered for the last 2 seconds The IPC receives a GMLAN message from the ECM. The distance information is calculated by the IPC using the vehicle speed information from the ECM. These values are retained during ignition OFF and can be changed between English and Metric units accessing the DIC English/Metric menu. The IFE display cannot be reset. Tire Pressure Monitor The IPC receives a GMLAN message from the tire pressure monitoring (TPM) system for front and rear tire pressure data. The DIC will display the pressure for each of the front and rear tires. When a tire with low air pressure is present, the DIC displays XXXX XXXX TIRE PRESSURE LOW. Trip Time The timer records elapsed time starting from activation. When the DIC displays the timer, pressing the Set/Reset switch for 1 second on the DIC resets the timer. Pressing the Set/Reset button on the DIC switch for approximately 1 second starts and stops the timer. The DIC displays the timer in one of the following formats: Page 3940 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 9511 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9735 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 16779 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 15068 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8104 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 3049 4. Remove the CKP sensor bolt and sensor. Installation Procedure Important: When installing the CKP sensor, make sure the sensor is fully seated before tightening the bolt. A poorly seated CKP sensor may perform erratically and may set false diagnostic trouble codes (DTCs). Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CKP sensor, install a NEW O-ring seal onto the sensor. 2. Lubricate the O-ring seal with clean engine oil. Notice: Refer to Fastener Notice. 3. Install the CKP sensor and bolt. Tighten the bolt to 10 N.m (89 lb in). Restraints - Air Bag Readiness Light On. Malfunction Lamp / Indicator: Customer Interest Restraints - Air Bag Readiness Light On. TECHNICAL Bulletin No.: 09-09-41-005 Date: June 26, 2009 Subject: Air Bag Readiness Light On, Service Air Bag Message, Inflatable Restraint Sensing and Diagnostic Module (SDM) Corrosion (Replace SDM/Cut and Remove Carpet Pad) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the Air Bag Readiness Light is on. There may also be a Service Air Bag Message on the Driver Information Center (DIC). Upon further investigation, the Sensing and Diagnostic Module (SDM) may be corroded. Cause This condition may be caused by an unseated parking brake cable grommet causing water intrusion under the carpet or vinyl floor, resulting in wet padding. Power washing the vinyl floor and/or customer snow boots can introduce water to the padding above the SDM area. As the padding gets wet, water wicks through the padding towards the SDM over time. Over an extended period of time of constant exposure to water with potential salt/calcium and other elements, the SDM surface starts to corrode. Correction 1. Replace the SDM per SI procedures. Refer to Inflatable Restraint Sensing and Diagnostic Module Replacement in SI. 2. Inspect the SDM connector for corrosion. If corrosion is evident, repair or replace the connector. Refer to SIR/SRS Wiring Repairs in SI. 3. Verify the parking brake cable grommet is sealed properly. Important Cut and remove the padding from around the SDM as instructed whenever the SDM is serviced even if no corrosion is evident to prevent future moisture and corrosion to the SDM and connector. 4. Cut and remove padding from the area around and above the SDM. Refer to illustration above. Make an addition cut to remove all of the padding above the SDM. Parts Information Refer to Group Number 16.712 (Inflatable Restraint System) of the GM Parts Catalog for the appropriate service parts. Warranty Information For vehicles repaired under warranty, use the table above. Page 10357 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 21967 4. Insert a suitable tool (1) into the sunshade cam locking hole (2). 5. Turn the sunshade (1) counterclockwise until the shade cam (2) is align with the bracket (3) notch. Page 10636 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 173 Page 3909 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 9026 Page 8286 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 13696 18. Install the range selector cable heat shield. Notice: Refer to Fastener Notice. Important: Install bolts by hand then mechanically tighten the front bolt first and the rear bolt last. Failure to tighten the bolts in the specified order will result in misalignment of the heat shield. 19. Install the range selector cable heat shield bolts. Tighten the front bolt to 25 N.m (18 lb ft). Tighten the rear bolt to 25 N.m (18 lb ft). 20. Lower the vehicle. 21. Test the transmission for proper shift operation. 22. If all of the gear positions cannot be achieved, adjust the cable. Page 5013 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 10079 Canister Vent Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Valve Replacement (Extended Cab w/26 Gal Tank) Evaporative Emission Canister Vent Solenoid Valve Replacement (Extended Cab w/26 Gal Tank) Removal Procedure Important: Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove EVAP canister vent solenoid clip (1) from the chassis EVAP line. 3. Remove the EVAP canister vent solenoid pipe from the clip (2) on the chassis EVAP line. 4. Remove the EVAP canister vent solenoid pipe from the clips (3) on the brake pipes. 5. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid. Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Important: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 24609 2. Install the windshield washer container assembly. 3. Install the upper windshield washer container bolt to the auxiliary battery tray, if equipped. Notice: Refer to Fastener Notice. 4. Install the upper windshield washer solvent container bolts. Tighten the bolts to 9 N.m (80 lb in). 5. Install the auxiliary battery tray, if equipped. 6. Install the windshield washer solvent cap. 7. Connect the electrical connectors. 8. Connect the washer pump hoses (1, 2). 9. Install the lower outer washer container bolt. 10. Install the left front wheelhouse liner. 11. Install the left front wheel assembly. Page 7149 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 13205 12. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: * Clutch material * Bronze slivers indicating bushing wear * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. 4. Install the oil pan and NEW gasket. Page 2143 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 13880 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 9514 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 7827 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 5113 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. HVAC - Automatic Control Assembly: Service and Repair HVAC - Automatic HVAC Control Module Replacement Page 462 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 2792 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 7500 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 4412 Models Supercede: This bulletin is being revised to add model years, models and additional information. Please discard Corporate Bulletin Number 00-00-89-008E (Section 00 - General Information). Some customers may want to tow their vehicle behind another vehicle with all FOUR tires on the ground. This is referred to as "dinghy" towing. Towing in this manner is acceptable only on the certain vehicles. The vehicle should be properly equipped and prepared as described below. The passenger cars listed above are the vehicles that CAN be dinghy towed. Passenger cars not listed above are vehicles where dinghy towing is not permitted or recommended. Certain 4WD trucks can be dinghy towed depending on the transfer case option. Rear wheel drive and AWD trucks should NOT be dinghy towed. Refer to the truck models and transfer case options below. Please refer to the applicable vehicle Owner's Manual before towing. Passenger Cars Page 3967 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 6899 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 21476 Scuff Plate: Service and Repair Rear Side Door Sill Plate Replacement (Extended Cab) Rear Side Door Sill Plate Replacement (Extended Cab) Page 3602 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Page 7305 Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face the engine front cover. Failure to do so will damage the front cover and the reluctor ring. 1. Install the CKP sensor reluctor ring. 1. Align the keyway on the CKP sensor reluctor ring with the key in the crankshaft. 2. Using J 5590, push the CKP sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. 2. Install the engine front cover. Page 18103 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 17168 Page 9379 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 1992 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 10661 4. Inspect for fuel leaks. Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 15086 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: * The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. * Apply the park brake. * The engine must start in the park (P) or neutral (N) positions only. * Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 7137 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8400 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 11114 Page 2748 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 11462 4. Remove the CKP sensor bolt and sensor. Installation Procedure Important: When installing the CKP sensor, make sure the sensor is fully seated before tightening the bolt. A poorly seated CKP sensor may perform erratically and may set false diagnostic trouble codes (DTCs). Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CKP sensor, install a NEW O-ring seal onto the sensor. 2. Lubricate the O-ring seal with clean engine oil. Notice: Refer to Fastener Notice. 3. Install the CKP sensor and bolt. Tighten the bolt to 10 N.m (89 lb in). Page 11862 Crankshaft Position Sensor: Connector Views Engine Controls Connector End Views Crankshaft Position (CKP) Sensor Page 8351 Body Control Module (BCM) X7 Page 15261 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Page 17309 X211 Instrument Panel Harness (Y91) Or I/P Extension Harness (-Y91) To Console Harness (Y91/UQA/D07) (Pin A1 To C6) Page 6654 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 16778 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 2738 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 4532 Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 10. Use the J 38606 if the clearance does not permit use of the J 5892-D. 11. Install the valve stem O-ring seal. 12. Install the valve stem keys. Use grease in order to hold the valve stem keys in place. 13. Carefully release the valve spring pressure, making sure the valve stem keys stay in place. Notice: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. 14. Remove the J 5892-D or the J 38606. 1. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. 2. Tap the end of the valve stem with a plastic faced hammer in order to seat the valve stem keys, if necessary. 15. Remove the J 22794. 16. Install the spark plugs. 17. Install the valve rocker arms. Page 8341 Page 7000 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Locations Knock Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 11186 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 9378 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 6853 Page 16485 X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) X321 Page 17148 Junction Block - Left I/P X8 Page 611 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 9319 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 5987 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 8598 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 3023 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 19541 Television / Monitor: Service and Repair Video Display Replacement (Second Row) Page 585 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 951 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 15136 Electronic Brake Control Module (JH6/JH7) Page 20344 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 17372 Page 19704 Page 9095 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 21362 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 24227 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 7991 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 14758 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Rear Axle Shaft Replacement (8.6 Inch Axle w/Drum Brakes NON-VSES) Axle Shaft: Service and Repair Rear Axle Shaft Replacement (8.6 Inch Axle w/Drum Brakes NON-VSES) Rear Axle Shaft Replacement (8.6 Inch Axle w/Drum Brakes NON-VSES) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear cover and gasket. 4. Remove the pinion shaft locking bolt. 5. On axles without a locking differential, remove the pinion shaft. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 17752 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 2812 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 7163 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Restraints - Seat Belt Latch Stop Button Availability Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission: * The torque converter clutch solenoid (1) * The pressure control solenoid (2) * The internal wiring harness (3) * The 2-3 shift solenoid (4) * The 1-2 shift solenoid (5) * The transmission fluid pressure manual valve position switch (6) * The 3-2 shift solenoid (7) * The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wiring harness electrical connectors from the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) Page 20517 Body Control Module (BCM) X2 Page 1665 Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 2190 Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 6191 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 13190 7. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis. See: Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E - Automatic Transmission/Fluid Leak Diagnosis 8. If the fluid level is in the acceptable range, push the dipstick back into the dipstick tube all the way, and then flip the handle down to lock the dipstick in place. 9. If applicable and if the vehicle is equipped, reset the transmission oil life monitor only if the fluid was changed. Fluid Condition Inspection Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the bottom pan for excessive metal particles or other debris. A small amount of "friction" material in the bottom pan is a "normal" condition. If large pieces and/or metal particles are noted in the fluid or bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission. See: Testing and Inspection/Symptom Related Diagnostic Procedures/4L60-E/4L65-E/4L70-E - Automatic Transmission/Engine Coolant/Water in Transmission Page 2948 Crankshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 14098 - The IP wiring branch to C202 may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been fully seated. Possible point of contact (2). - The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been fully seated. Possible points of contact (1, 2). - The IP wiring branch to C202 may have never been secured into place as the gray retaining clip (1) off the branch was never seated. Page 1937 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 16183 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 8550 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 2844 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 432 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 13181 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 21804 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 1649 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 11952 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Plate Replacement (Extended Cab) Rear Side Door Sill Plate Replacement (Crew Cab) . 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. Page 3611 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Page 16285 Junction Block - Right I/P X3 Page 22403 Page 12492 Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 2 (PCS2) Pressure Switch Manifold (PSM) Page 21858 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Locations Steering Angle Sensor: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Sunroof Sunshade Replacement (Extended Cab) Sun Shade: Service and Repair Sunroof Sunshade Replacement (Extended Cab) Sunroof Sunshade Replacement (Extended Cab) Removal Procedure Important: If the sunshade spring releases, it will be necessary to rewind it. Turn the sunshade roller end slot 20 times in the counterclockwise direction. Important: A new sunshade service part comes pre-loaded with a pin tool holding spring tension on the sunshade. If the sunshade spring releases, it will be necessary to rewind it and reinstall the pin tool. Following installation, retain the pin tool for future applications. 1. Remove the sunroof window. 2. Power the sunroof window guides to the fully open position. Important: The cam locking hole will come in to view when the sunshade is in the fully open position on the passengers side. 3. Close the sunshade (1) until the cam locking hole (2) come in to view. Page 10557 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 3469 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Page 24317 Power Window Switch: Service and Repair Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Campaign - Front And Rear Chrome Interior Door Handle Technical Service Bulletin # 09239A Date: 100825 Campaign - Front And Rear Chrome Interior Door Handle SPECIAL COVERAGE Bulletin No.: 09239A Date: August 25, 2010 Subject: 09239A - Special Coverage Adjustment - Front and Rear Chrome Interior Door Handle Lever Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL Equipped with Chrome Interior Door Handles Supercede: The Parts Information section has been revised to include a note that P/N 88880051 is used for the front and rear doors. Step 6 under the Rear Side Door Inside Handle Replacement procedure has also been revised to refer technicians to the Rear Side Door Inside Handle Replacement in SI.Please discard all copies of bulletin 09293, issued July 2010. Condition Some customers of 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles may comment about peeling on the top surface of the front or rear chrome interior door handle(s). A chrome plating irregularity combined with direct sunlight exposure may cause the plating to separate from the top surface of the handle on certain vehicles. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership or mileage. Dealers are to replace the front and/or rear chrome interior door handle levers if signs of peeling are present. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after July 16, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to July 16, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles built within the following VIN breakpoints: Page 20718 Parts Information Important: There are a total of seven (7) white retainers and four (4) black retainers used per door trim panel. The retainers are shipped one per package. The technician will need to determine how many of each retainer is necessary to complete the repair. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 379 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 17177 Fuse Block - Underhood X5 (Pin K4 To K8) Fuse Block - Underhood X6 Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 2135 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 19535 For vehicles repaired under warranty, use the table. Disclaimer Diagrams Combination Switch: Diagrams Lighting Systems Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Page 5873 Engine Control Module X1 (Pin 1 To 24) Page 16073 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 12201 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 23641 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 15683 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Page 6715 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 2877 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 19908 Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 9332 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 21392 Console: Service and Repair Center Console End Panel Replacement Center Console End Panel Replacement Floor Console Bezel Replacement Floor Console Bezel Replacement Page 10856 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 2512 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 9398 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 220 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 14244 3. Install the axle shaft seal using the J 21128. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. Page 18782 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended Cab +ASF) Inflatable Restraint Vehicle Rollover Sensor (ASF) Page 4343 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 17817 3. Place a pipe wrench on the steering gear rack (1) next to the steering linkage inner tie rod housing (2). Notice: Refer to Fastener Notice. 4. Tighten the steering linkage inner tie rod housing (2). Tighten the steering linkage inner tie rod to 100 N.m (74 lb ft). 5. Install the steering gear boot. Page 488 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 23119 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. HVAC - Automatic Low Pressure Sensor / Switch: Diagrams HVAC - Automatic HVAC Connector End Views A/C Low Pressure Switch Reverse Lockout Solenoid Page 15578 Page 22417 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 5175 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 17649 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 5035 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 7242 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 2280 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 11780 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 11291 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 5124 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 8939 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 12382 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Page 12709 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 10552 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Door Lock and Side Window Switch Replacement - Driver Side Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Resonator Replacement Removal Procedure 1. Disconnect the positive crankcase ventilation (PCV) hose (1) from the air cleaner outlet resonator. 2. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 3. Loosen the air cleaner outlet resonator clamp (2) at the throttle body. 4. Remove the air cleaner outlet resonator from the throttle body and the MAF/IAT sensor. Installation Procedure Page 10183 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 7237 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 10303 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Page 21855 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 2871 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 565 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 3660 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 7832 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 14275 18. Inspect the inboard stroke position. - Measurement A for the 1500 models should be 170 mm (6 11/16 inch). - Measurement A for the 2500, 3500, should be 178 mm (7 inch). 19. Install the wheel drive shaft. Refer to Wheel Drive Shaft Replacement See: Service and Repair. Page 21284 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2478 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4009 Page 6075 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 5350 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 6050 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 20090 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. OnStar(R) - False Crash Detection Customer Calling Emergency Contact Module: All Technical Service Bulletins OnStar(R) - False Crash Detection Customer Calling TECHNICAL Bulletin No.: 08-08-46-002 Date: June 26, 2008 Subject: OnStar(R) Calls Unwanted, False Crash Detection Customer Calling (Reprogram SDM) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with OnStar(R) (RPO UE1) Condition Some customers may comment on receiving unwanted calls from the OnStar(R) Center. Cause During certain extreme vehicle maneuvers, the vehicle SDM may mistakenly detect a crash event and generate a call to the OnStar(R) call Center. The OnStar(R) advisor is connected to the vehicle to see if everyone is alright and if a request for emergency help is needed. Correction A revised SDM Operating System software has been developed to address this issue. Reprogram the Sensing and Diagnostic Module (SDM) with the controller option described as "SDM Sensing and Diagnostic Module" under Operating System using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 511 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 560 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 10461 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 14337 Important: If the wheel hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the wheel hub seal must be replaced. 14. Install the wheel hub to the axle housing. 15. Install the adjusting nut to the hub using the J 2222-C. 16. Adjust the wheel bearings. 17. Install the axle shaft. 18. Install the brake caliper bracket. 19. Install the tire and wheel assembly. 20. Inspect and add axle lubricant to the axle housing, if necessary. 21. Lower the vehicle. Page 3088 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Windshield Outside Moisture Sensor Replacement Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Replacement Windshield Outside Moisture Sensor Replacement Page 11438 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6096 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 16461 X207 Inline Harness Connector End Views X207 I/P Harness to I/P Harness (6J4) Page 9487 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 8413 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11356 Page 17879 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Electrical - Various Electrical Malfunction/Systems Inop Trailer Warning Indicator: Customer Interest Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 14290 4. Install the spider assembly (2). 5. Using the appropriate tool, install the retaining ring (1). Important: Position the boot clamp so that it is at the small end of the boot. 6. Install the tripot assembly (1) and the boot clamp (2). 7. Place approximately half of the lubricant (2) in the boot (1) and the remaining half in the tripot housing (3). Important: Pinch the slightly by hand in order to distort it into an oval shape. Page 2746 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 16591 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 21643 Door Lock, Window and Lighting System References Page 7903 Page 22461 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 9941 Transmission Position Switch/Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 8306 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 2368 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 20793 Disclaimer Page 7541 Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 4819 For vehicles repaired under warranty, use the table. Disclaimer Page 2469 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 10166 4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 5. Install the air cleaner outlet resonator to the MAT/IAT sensor. 6. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). Page 13323 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (367A) and the 1-2 shift solenoid retainer (395). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. 4. Install the pressure control solenoid (377). Notice: Refer to Fastener Notice. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Page 18968 Seat Belt: Service and Repair Seat Belt Replacement - Center Rear (Crew Cab) Seat Belt Replacement - Center Rear (Crew Cab) Electrical - Various Rear Door Electrical Malfunctions Speaker: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 13942 Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Notice: Refer to Fastener Notice. 3. Install the speed sensor bolt (1). Tighten bolt to 12 N.m (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Page 20670 The DIC displays the timer in the following format: XX: XX:XX: The first XX represents hours elapsed, the second XX represents minutes elapsed, and the third XX represents seconds elapsed. The maximum range of the timer is 99 hours, 59 minutes, and 59 seconds. After the maximum range is reached, the timer displays all zeros (00:00:00). Park Assist Menu The park assist menu is displayed in the DIC. The DIC displays the current state of the park assist until the IPC receives a message indicating otherwise. The DIC displays (- - -) when communication with park assist is lost. English/Metric The English/Metric mode is used to toggle between English and Metric units and can be accessed through the driver information center (DIC) Vehicle Info switch. Trip A/B The trip odometer A or B can be accessed through the DIC Trip/Fuel switch function. Language The driver information center (DIC) is capable of displaying in 8 languages * English * German * Italian * French * Spanish * Arabic * Chinese * Korean Page 18060 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 15573 Trailer Brake Controller Module (TBCM) Page 15357 Caution: Refer to Brake Dust Caution. Caution: Refer to Brake Fluid Irritant Caution. Disassembly Procedure 1. Remove the brake caliper. 2. Drain all the brake fluid from the caliper. Important: The brake calipers use phenolic pistons with stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant System Capacities Page 12134 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 14208 3. Install the axle shaft seal using the J 21128. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. Page 8992 Engine Control Module X2 (Pin 1 To 30) Page 2624 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 2381 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 4920 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 3720 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 2803 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 2258 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 10248 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 12565 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 22872 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Crew Cab) Page 13041 1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. 2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850. 3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case. 4. Install the J 25025-B (2, 3) to the transmission case. Page 7567 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 24319 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Extended Cab) Rear Side Door Window Switch Replacement (Extended Cab) Page 8979 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 22233 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Page 20122 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 20885 occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 08-08-64-007 Date: 080513 Body - Outside Door Handle(s) Squeak When Operated TECHNICAL Bulletin No.: 08-08-64-007 Date: May 13, 2008 Page 17788 Installation Procedure 1. Install the steering shaft upper bearing to the steering column tilt head assembly. 2. Install the steering column shaft assembly. 3. Maneuver and push the steering column tilt head assembly (1) towards the steering column in order to lock the steering wheel lock shoes in place. 4. Lubricate the pivot pins (1) with GM P/N 12346293 (Canadian P/N 992723). 5. Firmly seat each pivot pin (1) into the steering column tilt head assembly. 6. Stake the steering column in 3 locations around each pivot pin. 7. Install anti-rotation pin J 42640. Page 10689 9. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis line. 11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 12. Install the fuel line clip (1) to the bracket on the automatic transmission. Page 8073 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 7354 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 14069 17. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 18. Remove the 7 valve body checkballs. Important: Some models do not have an outer spring. Note spring usage during removal. 19. Remove the accumulator cover bolts (58, 59). 20. Remove the 1-2 accumulator cover and pin assembly (57). Page 16750 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 15718 Auxiliary Battery Relay: Diagrams Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X1 (TP2) Page 17932 Disclaimer Page 5330 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 9396 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 10829 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11900 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 18465 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 19556 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Service and Repair Housing Assembly HVAC: Service and Repair HVAC Module Assembly Replacement Tools Required J 43181 Heater Line QC Release Tool Removal Procedure 1. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Using the J 43181 disconnect the inlet heater hose from the heater core. 1. Install the J 43181 to the heater core pipe. 2. Close the tool around the heater core pipe. 3. Firmly pull the tool into the quick connect end of the heater hose. 4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the inlet hose from the heater core. 3. Using the J 43181 disconnect the surge tank outlet hose from the heater core. 1. Install the J 43181 to the heater core pipe. 2. Close the tool around the heater core pipe. 3. Firmly pull the tool into the quick connect end of the heater hose. 4. Firmly grasp the heater hose. Pull the heater hose forward in order to disengage the surge tank outlet hose from the heater core. 4. Remove the upper intake manifold sight shield. 5. Remove the battery. 6. Remove the accumulator. 7. Remove the instrument panel carrier. Page 1067 Page 12560 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Interior - Lint Accumulation On Ebony Colored Seats Arm Rest: All Technical Service Bulletins Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Page 22870 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Page 18074 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 13427 Fluid Pressure Sensor/Switch: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 4096 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 23224 Driver/Vehicle Information Display: Service and Repair Driver Information Display Switch Replacement (with RPO SLT) Driver Information Display Switch Replacement (with RPO SLT) Page 1757 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Remove the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Important: DISCARD the old steering shaft lock plate ring. 2. Remove the following parts from the steering shaft: 1. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137. 2. Turn signal switch cancel cam position plate (2) 3. Turn signal switch cancel cam (3) Installation Procedure Page 2297 Knock Sensor: Description and Operation Knock Sensor (KS) System Description Purpose The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor (KS) system uses one or 2 flat response 2-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the control module through a low reference circuit. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Page 17572 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 15897 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 6620 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 20803 Disclaimer Page 7577 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 9503 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 13962 Important: 2008 Silverado or Sierra equipped with 6L90 (MYD) are built with this TCM calibration revision. 4. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. This new service calibration was released with TIS satellite data update version 7.5 or later, available July 22, 2007. As always, make sure your Tech 2(R) is updated with the latest software version. 5. After reprogramming the TCM, Service Fast Learn Adapts must be performed using the Tech2(R). Check and clear all DTCs that may have set as a result of the programming process. 2006-2008 Vehicles with a 6L50, 6L80 or 6L90 Transmission (MYB, MYC or MYD) (Except 2007 Silverado and Sierra w/6L90) 1. Inspect and note the transmission fluid level and condition. If the level is high or low, it should be corrected and the vehicle road tested to verify that the condition is still present. 2. Remove the transmission bottom pan to inspect for possible debris. ^ If debris is found, the transmission should be disassembled to determine the source. Repair or replace the transmission in the most economical method following guidelines in Corporate Bulletin # 02-07-30-029. ^ If no debris is noted in the oil pan, remove the control valve body assembly and proceed to the next step. 3. Disassemble the valve body to: ^ Inspect transmission filter for any cracks, holes or split seams that may allow air to be sucked into the pump. ^ Inspect the check balls for roundness ensuring that there are no flat spots. ^ Measure all the valve body bore plugs (328) for diameter. The specification is 11.502 mm +/0.004 mm. Undersize bore plugs should be replaced. ^ Inspect clutch select valve 2 (352) (Closest to the manual valve) in the lower valve body (351) for freedom of movement and travel. ^ Inspect CBR1/ C456 Reg Valve (327) in the upper valve body (321) for freedom of movement and travel. ^ Perform Control Solenoid Valve and Transmission Control Module Assembly Solenoid Performance Test (SI Document ID # 1618572) to determine if shift solenoid # 1 is functioning properly. Important: The seals included in plate kit, P/N 24236934 or 24238925, should be replaced when the valve body is assembled. Do not reuse the old seals. ^ Replace the spacer plate with the appropriate part number from the list below. This spacer plate makes use of a revised gasket to help reduce the occurrence of DTC P0751. This spacer plate is used in vehicles built November 17, 2007 or later. It will not resolve a DTC P0751 concern on a vehicle built November 17, 2007 or later. Parts Information Page 19301 Cellular Phone Microphone: Service and Repair Mobile Telephone Microphone Replacement Page 13373 For vehicles repaired under warranty, use the table. Disclaimer Page 17624 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Page 20717 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-110-010A Date: 080414 Interior - Front Door Panel Rattles Loose TECHNICAL Bulletin No.: 07-08-110-010A Date: April 14, 2008 Subject: EI07321 - Inner Door Panel Rattle Noise/Loose (Inspect/Replace Clips) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Supercede: This bulletin is being revised to end the need for technician feedback and to provide corrective action. Please discard Corporate Bulletin Number 07-08-110-010 (Section 08 - Body and Accessories). Condition Some customers may comment on any of the following conditions: ^ a rattling noise coming from inside the door or the door panel ^ a poor fit of the inner door panel ^ a loose door panel Cause Engineering has determined that some of the door panel clips may have been damaged during assembly. Correction DO NOT REPLACE THE DOOR TRIM PANEL. Remove the interior door panel and inspect the clips for damage. Replace the clips if necessary and reinstall the door panel. If the clips are not missing or damaged, it is possible to correct the customers concern by reinstalling the door panel, ensuring the clips are fully seated. In the event that the customers concern is NOT related to the clips or corrected by reinstalling the door panel submit a Field Product Report (refer to bulletin # 02-00-89-002F). This information will provide engineering with the cause and correction of the customers complaint. Page 15209 Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JD9) Page 10949 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 18127 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 3380 Transmission Mode Switch: Locations Shift Lock Control Component Views Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 5048 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 2390 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 1353 Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Page 1774 Page 3299 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Page 2411 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 1846 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 5713 Body Control Module (BCM) X4 Page 6879 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 23372 Parts Information Warranty Information For IP clusters replaced/programmed due to customer satisfaction concerns of poor backlighting, the warranty claim MUST be submitted using the labor operation listed in this bulletin. Disclaimer Page 24036 Brake Light Switch: Diagrams Trailer Brake Control Trailer Brake Control Connector End Views Trailer Brake Controller Solid State Relay Trailer Brake Controller Solid State Relay Trailer Brake Control Panel Switch Page 15565 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 14222 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 15. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388 (8.6 inch, 9.5 inch axles) or the J 44414 (10.5 inch, 11.5 inch axle). 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. 3. Install the pinion yoke. Align the marks made during removal. Notice: Refer to Pinion Flange/Yoke Installation Notice. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. Notice: Refer to Fastener Notice. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 7. Tighten the pinion nut while holding the J 8614-01. Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Page 3680 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Page 24692 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 6896 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 6183 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 8137 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 2736 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 5414 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 5058 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 22953 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 17397 Page 9880 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 21881 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 21277 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 15252 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Page 6150 Page 1778 Page 2025 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 22852 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 16454 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Page 618 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 14787 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 11866 4. Connect the engine wiring harness electrical connector (4) to the CKP sensor. 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. 7. Perform the crankshaft position system variation learn procedure. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 9079 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 21573 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 14121 7. Inspect how the IP branch to C202 is routed. Reroute the harness as necessary to match the correct routing in the photo as shown. In order to route the IP harness branch correctly (behind the junction block-left I/P), remove the cover from the junction block-left I/P, unseat the junction block from the bracket. 8. Disconnect C202. Route the harness such that it lies between the "goalposts" of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). 9. Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 11. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness at Left Side Junction Block Mounting Bracket 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 4. Inspect for chafed/shorted wiring at the mounting bracket. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Replace the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Adjustable Pedals Motor 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Inspect the wiring harness for chafed/shorted wiring at the adjustable pedals motor as shown. 4. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Transmission 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Support the transmission with a transmission jack. 5. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. Page 11802 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 13796 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 13241 Fluid Pan: Specifications Allison - Automatic Transmission Oil Pan Install the 10 remaining oil pan bolts (8). Tighten the bolts to .............................................................................................................................. .................................................. 27 N.m (20 lb ft). Page 890 Auxiliary Body Control Module (XBCM) X1 (Export) Page 11065 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 12562 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 12401 Transmission Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Turbine Speed Sensor Page 21022 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Radiator Hose Quick Connect Fitting Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure Important: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. 1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection. Page 21185 Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (4WD 2500 HD, 3500) Drivetrain and Front Suspension Frame Front Crossmember Replacement (4WD 2500 HD, 3500) Page 22324 Seat Cushion: Service and Repair Front Seat Cushion Center Cover Replacement Front Seat Cushion Center Cover Replacement Page 4974 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 5189 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 1119 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 16096 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 3168 Page 6410 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 10944 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 18952 Disclaimer Page 19127 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Page 5081 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 18912 Inflatable Restraint Sensing and Diagnostic Module (SDM) (10 Series -ASF) Page 11541 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 2992 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 24735 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 5131 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 8437 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 6895 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 11215 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 5024 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 17109 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12899 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 16130 Page 14239 Notice: Refer to Fastener Notice. 5. Tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure the inner bearing and the seal seats against the spindle shoulder. Tighten the adjusting nut to 70 N.m (52 lb ft). 6. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C. 7. Turn the adjusting nut clockwise until the nut contacts the bearing cone. Torque on the nut must be zero to finger tight. 8. Insert the adjusting nut lock key into the keyway using one of the following procedures: * If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle. Important: Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle. * If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key. 9. Install the retaining ring. 10. Install the axle shaft. 11. Inspect the lubricant level and add, if necessary. 12. Lower the vehicle. Page 7614 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 8640 7. Remove the HO2S pigtail electrical connector clip (9) from the fuel line bracket. 8. Remove the HO2S (1). Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (1). Electrical - Various Rear Door Electrical Malfunctions Fuse: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 18908 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10418 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 2627 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 11533 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Page 23626 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 9473 View of the connector when released from the component. View of another type of Micro 64 connector. Page 5060 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 4L60-E/4L65-E/4L70-E - Automatic Transmission Clutch Control Solenoid Valve: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 9083 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 13262 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). Tighten the bolts to 10 N.m (89 lb in). Ball Check Valves 5. Install the 7 checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Drivetrain - Bump/Clunk Noise at Stop Or From Launch Slip Yoke: Customer Interest Drivetrain - Bump/Clunk Noise at Stop Or From Launch TECHNICAL Bulletin No.: 09-04-17-002E Date: January 14, 2011 Subject: Bump Feel/Clunk Noise at Stop or from Launch (Clean/Lubricate Propeller Shaft Slip Yoke Splines) Models: 2007-2008 Chevrolet Avalanche, Suburban 2007-2009 Chevrolet Tahoe 2007-2010 Chevrolet Silverado (New Body Style) with Single-Piece Propshafts 2007-2008 GMC Yukon XL 2007-2009 GMC Yukon 2007-2010 GMC Sierra (New Body Style) with Single-Piece Propshafts All Equipped with 4L60 Automatic Transmission (RPO M30) and 2WD Attention: This bulletin contains a procedure to clean/lubricate the slip yoke splines and replace the slip yoke, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the slip yoke. Supercede: This bulletin is being revised to update the warranty statement. Please discard Corporate Bulletin Number 09-04-17-002D (Section 04 - Driveline/Axle). Condition Some customers may comment that the vehicle has a bump feel or a clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind. Cause This condition may be caused by a slip/stick condition in the interface between the rear propshaft slip yoke and the transmission output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transmission while the vehicle rebounds slightly backward after stopping its momentum and create this condition. Correction Note Do not use the grease from this bulletin for lubrication of the slip yoke splines on 2WD MYC 6 Speed Transmissions or any 4WD vehicles. The output shaft in a 2WD MYC 6 Speed Transmissions or a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transmission or the transfer case and mixing with the fluid inside. The new grease is not compatible with the automatic transmission fluid (ATF) and can cause damage if mixed. Please refer to Corporate Bulletin Number 09-04-21-003B for repairing the bump feel or clunk noise condition on 4WD vehicles. Note A bump feel or noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic. Verify the customer's concern. Clean/Lubricate Slip Yoke Splines 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 2. Inspect the rear slip yoke splines on the drive shaft. 3. Clean the slip yoke splines with brake cleaner or equivalent and a shop towel. 4. Assure the yoke is free of rust or other foreign material. 5. Lubricate the slip yoke spline with grease, P/N 19257121 (in Canada, 19257122), using a brush or swab to completely cover the entire spline with a light coating of grease. Page 12137 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 6438 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 15586 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (JF3/JF7) Electronic Brake Control Module (JF3/JF7) Page 8565 View of the connector when released from the component. View of another type of Micro 64 connector. Page 3912 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 18053 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 5962 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 18882 Malfunction Lamp / Indicator: Diagrams SIR Connector End Views Inflatable Restraint Passenger Air Bag On/Off Indicator (AL0/C99) Page 7236 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 16522 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15459 6. Lower the vehicle. 7. Apply and release the park brake pedal 3 times. Locations Central Control Module: Locations Entertainment/Communication Component Views Behind the I/P 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 +YE9) 6 - Digital Radio Receiver (U2K) Page 7878 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 2505 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 17991 Notice: Refer to Fastener Notice. 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 N.m (62 lb in). Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. Install the tire on the wheel. Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 8156 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 21995 Tighten the screws to 4 N.m (35 lb in). 2. Install the motor/actuator. Tighten the motor attachment screws to 3.5 N.m (31 lb in). 3. Connect the electrical connector to the motor/actuator. 4. Remove the pin (1) from the holes that held the position while installing the drive motor. 5. Install the headliner. 6. Perform the Initialization/Teach Procedure. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor). See: Testing and Inspection/Programming and Relearning See: Testing and Inspection/Programming and Relearning See: Testing and Inspection/Programming and Relearning See: Testing and Inspection/Programming and Relearning 7. Verify the operation of the sunroof. Page 21578 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 22058 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Instruments/Audio - No Speaker Audio/Warning Chimes Audible Warning Device: All Technical Service Bulletins Instruments/Audio - No Speaker Audio/Warning Chimes Bulletin No.: 07-08-44-008 Date: April 18, 2007 TECHNICAL Subject: No Audio/No Sound Heard from Radio Speakers, Turn Signals, Hazard Signals and No Warning Chimes When a Door or Liftgate is Opened (Inspect/Seat C2 Audio Amplifier Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Speakers, Premium Audio w/Amplifier or Rear Stereo Audio (RPOs UQA, UQS or UK6) Condition Some customers may comment on one or all of the following conditions related to no audio/no sound: No sound from one or more of the radio speakers. No blinking sound heard form the turn signals or hazard signals when on. No audio warning chimes heard when a door or liftgate is opened. Cause The C2 Audio Amplifier Connector may become unseated at the amplifier. Correction Inspect/Seat the C2 Audio Amplifier Connector (16-way, Black Connector). Remove the radio, amplifier, and SIR fuses located in the Underhood Bussed Electrical Center (BEC). Gain access to the radio speaker amplifier. Refer to Radio Speaker Amplifier Replacement in SI. Page 11600 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 6481 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 10923 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 23653 Page 20523 Body Control Module (BCM) X7 Page 7552 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of A/C - Indicators Flashing (Normal Condition) Control Assembly: All Technical Service Bulletins A/C - Indicators Flashing (Normal Condition) Bulletin No.: 07-01-38-003 Date: June 12, 2007 INFORMATION Subject: Information for Vehicles with HVAC Control Module A/C And Recirculation Indicators Flashing Models: 2008 Buick Enclave 2007-2008 Cadillac Escalade Models 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2007-2008 GMC Acadia, Sierra, Yukon Models 2007-2008 Pontiac Torrent 2008 HUMMER H2 2007-2008 Saturn OUTLOOK 2008 Saturn VUE Condition/Concern Some customers may comment that the Air Conditioning (A/C) indicator on the Heating Ventilation and Air Conditioning (HVAC) Control Module flashes then turns off after they press the A/C button. Others may comment that the Recirculation indicator on the HVAC Control Module flashes then turns off after they press the Recirculation button. This is normal operation for the HVAC Control Module and indicates that the A/C or Recirculation function is not available at this time. Reasons that the A/C may not be available (calibrated values vary by program) are listed below. Consult the appropriate vehicle Service Information (SI) for detailed HVAC Description and Operation: Ambient Air Temperature is too low (if equipped with Ambient Air Temperature Sensor) Vehicle voltage less than 9.5 volts Refrigerant Pressure too low Refrigerant Pressure too high Engine Coolant Temperature too high Engine is not in RUN HVAC Control Head is in the OFF position Reasons Recirculation may not be available: Mode switch in Floor, Defog or Defrost mode. The reason(s) A/C is currently disabled can be viewed with a Tech 2(R) by navigating to HVAC Data display and viewing the "A/C Permission" parameter. Recommendation/Instructions Do not replace the HVAC Control Module for a flashing A/C Indicator or flashing Recirculation Indicator, as this is normal operation. Disclaimer Page 21564 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 263 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 12252 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 8974 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 22487 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 4354 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 12469 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 938 Page 16978 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 12499 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (367A) and the 1-2 shift solenoid retainer (395). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. 4. Install the pressure control solenoid (377). Notice: Refer to Fastener Notice. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Application and ID Turn Signal Flasher: Application and ID This vehicle does not use a traditional hazard/turn signal flasher. This function is controlled by the Body Control Module (BCM). Page 13185 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSMISSION DEXRON-VI Automatic Transmission Fluid. Page 11100 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 12544 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 24170 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 22234 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10279 Air Flow Meter/Sensor: Connector Views Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 6084 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 6906 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 7467 4. Loosen the air cleaner housing screws. 5. Lift up the air cleaner housing cover. 6. Remove the air filter element. Installation Procedure 1. Insert the NEW air filter element. 2. Install the air cleaner housing cover. Notice: Refer to Fastener Notice. 3. Tighten the air cleaner housing screws. Tighten the screws to 3 N.m (27 lb in). Page 17166 Fuse Block - Underhood X1 Page 4705 26. Place the engine wiring harness rear bracket onto the upper intake manifold and install the bolts. Tighten the bolts to 10 N.m (89 lb in). 27. Install the engine wiring harness clips (1, 2) to the engine harness brackets. Page 3536 * The areas surrounding the connections Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 3484 4. Set the top edge of the level on the reference surface of the steering knuckle (C) and extend the level directly under the rear end of the front attachment bolt of the lower control arm (A). 5. While keeping the level in contact with the knuckle reference surface, adjust the level up/down until the bubble indicates it is horizontally level. 6. Extend a tape measure straight down from the center of the attachment bolt. The point where the tape measure and the level intersect is your first measurement. 7. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the front end of the rear attachment bolt of the lower control arm (B). 8. Extend a tape measure straight down from the center of he attachment bolt. The point where the tape measure and the level intersect is your second measurement. 9. Push the front bumper of the vehicle down about 38 mm (1.5 in) 10. Gently remove your hands and let the vehicle settle. 11. Repeat this operation 2 more times for a total of 3 times. 12. Re-measure the Z height. 13. The true Z height is the average of the measurements taken. Refer to Trim Height Specifications. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Z Height Adjustment 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion arm as needed. One revolution of the bolt (1) into the nut increases the Z height by approximately 6 mm (0.2 in). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. 3. If these measurements are still out of specifications after adjustment or are not equipped with torsion bars, inspect for the following: * Sagging front suspension-Refer to Torsion Bar and Support Assembly Replacement (Bushing Style). * Collision damage Page 12999 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Service and Repair Parking Light Bulb: Service and Repair Park/Turn Signal Lamp Bulb Replacement (Chevrolet) Page 7836 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 3154 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 22468 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 10567 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Air Temperature Sensor Replacement - Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Left Side Air Temperature Sensor Replacement - Lower Left Side Page 12978 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21131 Endgate Emblem/Nameplate Replacement (Chevrolet) Endgate Emblem/Nameplate Replacement (Chevrolet) Page 23654 Courtesy Lamp: Service and Repair Outside Rearview Mirror Courtesy Lamp Replacement Page 20663 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 22221 Rear Seat Back Recliner Cover Replacement (Extended Cab with A68) Rear Seat Back Recliner Cover Replacement (Extended Cab with A68) Page 7415 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 9626 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11794 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 14684 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (367A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Radiator Air Baffle and Deflector Replacement - Upper Radiator: Service and Repair Radiator Air Baffle and Deflector Replacement - Upper Radiator Air Upper Baffle and Deflector Replacement Removal Procedure 1. Remove the radiator air upper baffle retainers (Qty 8). 2. Remove the radiator air upper baffle. Installation Procedure 1. Install the radiator air upper baffle. 2. Install the radiator air upper baffle retainers (Qty 8). Page 5803 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 23587 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 24284 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Extended Cab) Rear Side Door Window Switch Replacement (Extended Cab) Page 3911 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 4320 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Instruments Nav. Radio Clock/Clock Tab Malfunctions Navigation System: All Technical Service Bulletins Instruments Nav. Radio Clock/Clock Tab Malfunctions Bulletin No.: 08-08-44-002 Date: February 15, 2008 TECHNICAL Subject: Navigation Radio Clock and/or Clock Tab Do Not Appear or Disappears Intermittently (Update Navigation Radio with New Software) Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008 HUMMER H2 with Radio RPO UVB or U3U Condition Some customers may comment that the clock and/or the clock tab does not appear on the navigation screen. Cause This condition may be caused by a software anomaly, which causes the clock and/or clock tab to disappear during the ignition key cycle. Correction DO NOT REPLACE THE NAVIGATION RADIO. Using the Tech 2(R), verify that the vehicle is equipped with one of the following radio part numbers: If the vehicle is not equipped with one of the following radio part numbers, disregard this bulletin. 15882766 15882767 15940102 15940103 25797978 25834072 Update the Navigation Radio's software to correct this condition. This software upgrade will also update some operating characteristics on the Navigation Radio. The following functions or displays may be affected: Inform the customer that stored destinations and radio presets may not be retained during programming. clock font size text color on light colored screens split screen icon to minimize the "Points of Interest" popup and "Exit" popup change driver locked out features when the vehicle is out of "Park" "back" button on street address entry screen for entering street number How to Obtain Nav Software Update Disc (P/N 25956121 - software version 0B92): Software discs are available through the GM Nav Disc Center. Dealers should retain the disc for use in repairing future vehicles. DO NOT give the software disc to the customer. Page 1825 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 16701 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 16164 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 21721 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Locations Fuel Tank Pressure Sensor: Locations Engine Controls Component Views Near the Fuel Tank 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (- Diesel) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Line Pressure Sensor (-LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly - Front (Gas) Page 3652 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 19336 Vehicle Communication Interface Module (VCIM) X3 (UE1 +U3U/UVB) Page 16962 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 12588 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 15747 2. Install the auxiliary battery positive cable push nuts (6). 3. Install the auxiliary battery positive cable retainer (2) to the stud on the front of dash. Notice: Refer to Fastener Notice. 4. Install the auxiliary battery positive cable and nut (4) to the battery relay. Tighten the nut to 9 N.m (80 lb in). 5. Position the auxiliary battery positive cable boot (5). 6. Connect auxiliary battery positive cable electrical connector (1) to the auxiliary battery relay. 7. Install the auxiliary battery positive cable to the mega fuse holder. 8. Install the generator battery jumper cable terminal (2) to the mega fuse stud. 9. Install the generator battery jumper cable nut (3) to the mega fuse holder. Tighten the nut to 9 N.m (80 lb in). Page 2325 Page 11287 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 12591 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Procedures Clockspring Assembly / Spiral Cable: Procedures Inflatable Restraint Steering Wheel Module Coil Centering Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: If double wire harness strap is installed onto the wire harness assembly and column, you must reuse the holder for the wire straps during installation. Remove the wire harness strap(s) where necessary. 1. Verify the following conditions before centering the SIR coil: * The wheels on the vehicle are straight ahead. * The block tooth (1) of the steering shaft assembly is in the 12 o'clock position. * The ignition switch is in the LOCK position. 2. The front of the SIR coil has a centering window (1). To center the SIR coil perform the following steps: 1. Hold the SIR coil with the face up. 2. Rotate the coil hub clockwise until the coil ribbon stops. 3. Rotate the coil hub slowly, counterclockwise until the centering window appears yellow (1) and both arrows (2) line up. This is the CENTER position. 4. While holding the coil hub in the CENTER position, align the SIR coil with the horn tower and slide onto the steering shaft assembly. 3. If a double wire harness strap is installed onto the wire harness assembly and column, you must route the wires up against the steering column. One wire harness strap will surround one lead from the coil to the steering column. The other wire harness strap will surround all other leads to the steering column. Page 24274 Power Window Switch: Diagrams Window Systems Connector End Views Window Switch - Driver X1 (A31 -AN3/DL3) Window Switch - Driver X2 (A31 -AN3/DL3) Page 4653 1. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive to both the right and left sides of the front cover to engine block junction at the oil pan sealing surfaces. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 2. Apply a 5 mm (0.197 in) wide and 25 mm (1.0 in) long bead of adhesive to the entire length of rear oil seal housing to engine block junction at the oil pan sealing surfaces. Refer to Sealers, Adhesives, and Lubricants for the correct part number. Page 6987 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 23076 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 19112 1 - Window Switch - Right Rear (ABV) 2 - Window Motor - Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 4 - Speaker - Right Rear Door Left Rear Door (Crew Cab) Page 12623 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Page 10821 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 10395 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 23642 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 23895 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11532 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Electrical - Battery Goes Dead Overnight Body Control Module: Customer Interest Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Center Pillar Assist Handle Replacement Passenger Assist Handle: Service and Repair Center Pillar Assist Handle Replacement Center Pillar Assist Handle Replacement Page 8646 Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (2). Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S pigtail electrical connector (5) to the engine wiring harness electrical connector (4). 4. Install the CPA retainer. 5. Lower the vehicle. Page 7908 Crankshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 7966 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 8576 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 10733 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 16271 Junction Block - Left I/P X2 (Pin A1 To E2) Service and Repair Fuel Filler Neck: Service and Repair Fuel Tank Filler Pipe Housing Replacement Page 17028 Page 22212 Page 23680 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 14960 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 10269 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 5985 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 15753 7. Install the starter solenoid cable terminal (2) to the fuse stud. 8. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 9 N.m (80 lb in). 9. Install the mega fuse cover. 10. Connect the auxiliary battery negative cable. Locations Cabin Temperature Sensor / Switch: Locations HVAC Component Views Front Headliner Components 1 - Inside Air Temperature Sensor - Front (CJ2) 2 - Cellular Microphone (UE1/U3U/UVB) 3 Courtesy/Reading Lamps - Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade - Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly 8 - Inside Rearview Mirror (ISRVM) 9 - Courtesy/Reading Lamps - Front 10 - Windshield 11 - Sunshade - Left (DH6) Locations Seat Position Sensor: Locations SIR Component Views Driver Seat 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (AN3) Page 13207 Fluid Filter - A/T: Service and Repair Allison - Automatic Transmission Transmission Fluid Filter Adapter Replacement Transmission Fluid Filter Adapter Replacement Removal Procedure Important: * DO NOT drain the fluid if only the transmission external oil filter adapter is being replaced. * Use a standard strap-type filter wrench to remove or install the transmission external oil filter. Remove the transmission external oil filter (4) by rotating in the counterclockwise direction. 1. Remove the magnet (2) from the transmission external oil filter adapter (1) in the converter housing or from the filter element. 2. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. 3. Remove the filter adapter (1) from the converter housing. Installation Procedure 1. Install the transmission external oil filter adapter (1). Notice: Refer to Fastener Notice. Tighten the adapter to 30 N.m (22 lb ft). 2. Reinstall the magnet (2) onto the filter adapter (1). 3. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 4. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 5. Turn the filter ONE FULL TURN ONLY after gasket contact. Notice: Use only clean and approved transmission fluid. 6. Check the transmission fluid level. Page 6243 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 8511 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. Notice: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 2. Remove the MAP sensor bolt (1). 3. Using a slight rocking motion while pulling straight up, remove the MAP sensor (2) from the upper intake manifold. 4. Inspect the MAP sensor seal for damage, replace the seal if necessary. Installation Procedure Page 8538 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 135 Entertainment System Control Module: Diagrams Entertainment/Communication Connector End Views Infrared Module (U42) Page 23916 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 19331 Disclaimer Page 1827 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 9522 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 7109 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 18023 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 9559 4. If installing the old sensor, apply sealant to the threads of the sensor. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 5. Using J 41712, install the sensor. Tighten the sensor to 30 N.m (22 lb ft). 6. Connect the fuel pump/oil pressure sensor electrical connector (3). 7. Check and adjust the engine oil level, if necessary. Page 22007 Notice: Refer to Fastener Notice. 4. Install the water gutter screws (1). Tighten the screws to 2 N.m (18 lb in). 5. Install the sunroof module. 6. Open the sunroof window to the fully open position. 7. Install the air deflector. 8. Remove the tape from around the perimeter of the sunroof window. 9. Verify that the sunroof is operating properly. Lighting - Dome/Reading Lamps Inoperative Washer Fluid Heater: All Technical Service Bulletins Wipers/Washers - Heated Washer Fluid System Operation Bulletin No.: 07-08-43-009 Date: August 14, 2007 INFORMATION Subject: Heated Windshield Washer Fluid System Operation - Unwanted Activation of the Front Windshield Washers Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Heated Windshield Washer Fluid System (RPO XA7) The purpose of this bulletin is to further explain information found in SI and the Owner's Manual about the operation of the Heated Windshield Washer Fluid System. Operation: Push the heated washer fluid button to activate the heated windshield washer fluid system. This activation begins four heated wash/wipe cycles. The first heated wash/wipe cycle can take up to 40 seconds to occur, depending on outside temperature. After the first wash/wipe cycle, it can take up to 20 seconds for each of the remaining cycles. To end the heated windshield washer/wipe cycle early press the button again to turn off the heated windshield washer fluid system or it will automatically turn off after four wipe cycles have been completed. Diagnostic Tips: If a customer comes in with a comment about unwanted activation of the front windshield washers, first verify that the heated washer fluid switch was not pressed. Some customers may be unknowingly turning on the heated windshield washers. The heated windshield washer button is located below the HVAC controls and if personal items are placed on the center console, it is possible to inadvertently activate the heated washers. If the switch was not pressed and the washers/wipers continue to cycle with no switch input, observe the Wiper/Washer data using the Tech 2(R). When the concern is happening, it will display the "Windshield Washer Switch" as active even though the switch is not being pressed. This may be caused by an intermittent short in the heated washer fluid module. It has been found, during part reviews of the heated windshield washer module at the Warranty Parts Center (WPC), that a large number of parts returned are no trouble found (NTF). Some of these NTF returns may be due to mis-diagnosis or from customers not fully understanding how the heated windshield washer fluid system operates. The information in this bulletin is being provided to help reduce the NTF returns. Disclaimer Page 9231 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Service and Repair Power Steering Pressure Control Valve: Service and Repair Power Steering Pump Flow Control Valve Replacement - Off Vehicle Page 26 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 12985 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 18660 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 4553 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 502 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 5862 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 5281 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 1814 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 6392 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 16783 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 22921 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 20922 5. Install the new roll pin that is included in the door handle kit, P/N 88880051. 6. Install the rear side door inside handles. Refer to Rear Side Door Inside Handle Replacement in SI. Customer Information 1. Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition covered under this Special Coverage are to be submitted to the dealer prior to or by July 31, 2011. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Page 2943 Page 12203 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Locations Steering Angle Sensor: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 11030 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 7133 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 11691 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 7155 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 23386 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 14968 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 9739 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 7383 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 8700 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 8393 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Locations Shift Interlock Solenoid: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 12209 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8552 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 15242 Page 20837 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8819 For vehicles repaired under warranty use, the table. Disclaimer Page 16882 Page 19171 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 434 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 19983 Amplifier: Diagrams Entertainment/Communication Connector End Views Audio Amplifier X1 (UQA -Y91) Audio Amplifier X1 (UQA +Y91) Page 9831 Page 12730 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 21869 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 4058 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2068 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 12114 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Stop Lamp Switch Replacement (Adjustable Pedal) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Adjustable Pedal) Stop Lamp Switch Replacement (Adjustable Pedal) Page 7576 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 17842 9. Remove the lower control arm nuts (1) and washers (2). 10. Remove the control arm bolts (3). 11. Remove the control arm (4). Installation Procedure 1. Install the lower control arm (4). 2. Install the lower control arm bolts (3). 3. Install the washers (2). Notice: Refer to Fastener Notice. 4. Install the lower control arm retaining nuts (1). Tighten nuts to 175 N.m (129 lb ft). 5. Install the lower ball joint in the steering knuckle. Page 13659 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 22313 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Page 2601 Page 9028 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 20734 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker (2) and the spacer, if equipped, in order to align the lower threaded hole in the striker backing plate. Notice: Refer to Fastener Notice. 7. Tighten the striker bolts. Tighten the door striker bolts to 24 N.m (18 lb ft). Page 9483 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21220 Notice: Refer to Fastener Notice . 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 N.m (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 N.m (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 N.m (74 lb ft). Page 2511 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 7260 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 21380 Page 16407 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness Page 10959 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 5783 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR Your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 6397 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 9060 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 5776 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 19340 Central Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Endgate Handle Replacement (Pickup Box) Tailgate Release Handle: Service and Repair Endgate Handle Replacement (Pickup Box) Endgate Handle Replacement (Pickup Box) Page 3235 Disclaimer Page 1094 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Locations Parking Brake Warning Switch: Locations Hydraulic Brake Component Views 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Page 11449 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 14051 374 - Actuator Feed Limit Valve 375 - Actuator Feed Limit Valve Spring 376 - Bore Plug 377 Pressure Control Solenoid Valve 378 - Pressure Control Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer Control Valve Body Assembly (2 of 2) Control Valve Body Assembly 340 - Manual Valve 350 - Control Valve Body Assembly 359 - Bore Plug 360 - Coiled Spring Pin 380 - Regulator Apply Valve 381 - Bore Plug 381 - Bore Plug 381 - Bore Plug 381 - Bore Plug 382 4-3 Sequence Valve Spring 383 - 4-3 Sequence Valve 384 - 3-4 Relay Valve 385 - 3-4 Shift Valve 386 - 3-4 Shift Valve Spring 387 - Reverse Abuse Valve 388 - Reverse Abuse Valve Spring 389 3-2 Downshift Valve 390 - 3-2 Downshift Valve Spring 391 - 3-2 Control Valve 392 - 3-2 Control Valve Spring 394 - 3-2 Control Solenoid Valve Page 14576 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Connect the internal wiring harness electrical connectors to the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) 23. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 24. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 2223 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 13803 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 519 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 16291 Junction Block - Rear Lamps X3 Junction Block - Rear Lamps X4 Page 11949 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Body - Chrome Outside Door Handle Loose/Cracked Rear Door Exterior Handle: All Technical Service Bulletins Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Restraints/Interior - Front Seat Belt Twisted Seat Belt: Customer Interest Restraints/Interior - Front Seat Belt Twisted TECHNICAL Bulletin No.: 07-09-40-001A Date: May 14, 2009 Subject: Front Seatbelt Latch Plate Reversed, Front Seatbelt Twisted (Perform Repair to Untwist Seatbelt) Models: 2008-2009 Buick Enclave 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2009 Saturn OUTLOOK .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the Traverse model and the 2009 model year. Please discard Corporate Bulletin Number 07-09-40-001 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the seatbelt latch plate is reversed on the belt webbing or that they have to twist the webbing before buckling the seatbelt. This condition can be visually verified by inspecting the location of the latch plate tongue. If the tongue is between the webbing and the pillar post, it is reversed. Correction Do NOT replace the seatbelt retractor for this condition. To correct this condition, perform the following repair. 1. Pull the majority of the belt webbing out of the retractor. 2. With the latch plate resting at its lowest point, take the webbing above the latch plate and fold the webbing over itself at a 45 degree angle. Pinch the folded portion between the thumb and forefinger. 3. Using the other hand, pull the latch plate up over the fold until past the doubled over section. Page 24199 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 22994 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11606 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 3786 6. Clean the drain plug. Installation Procedure Notice: Refer to Fastener Notice. 1. Install the rear axle drain plug. Tighten the rear axle drain plug to 33 N.m (24 lb ft). 2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. 3. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 4. Lower the vehicle. Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. Page 14765 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Locations Steering Angle Sensor: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Locations Fuel Tank Pressure Sensor: Locations Engine Controls Component Views Near the Fuel Tank 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (- Diesel) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Line Pressure Sensor (-LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly - Front (Gas) Page 10951 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4114 Fuse Block - I/P X1 Page 7006 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. JX200 - JX299 Branching Point: Diagrams JX200 - JX299 JX221 Splice Pack Connector End Views JX221 JX223 Splice Pack Connector End Views JX223 (-Y91 +U2K/UK6/UE1) Page 17381 X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (AZ3/D07 +UQ3) Page 13208 Automatic Transmission Fluid and Filter Replacement Automatic Transmission Fluid and Filter Replacement Removal Procedure Important: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. Important: Use a standard strap-type filter wrench to remove the transmission external oil filter. 3. Remove the filter (4) by rotating in the counterclockwise direction. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Notice: Refer to Fastener Notice. 5. Install the drain plug (6) and drain plug seal (5). Tighten the drain plug to 35 N.m (26 lb ft). 6. Refill Transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. Important: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. Page 9590 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 11834 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 13350 Transmission Control Module (TCM) 80-Way Connector (Part 1) Page 10474 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 17395 Page 7100 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12557 View of the connector when released from the component. View of another type of Micro 64 connector. Page 1677 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice. 2. Install the park brake warning lamp switch bolt. Tighten the bolt to 3 N.m (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. 5. Connect the negative battery cable. Page 10015 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 19597 Page 9204 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 9140 Diagrams Lateral Accelerometer: Diagrams Yaw Rate and Lateral Acceleration Sensor (JL4) Yaw Rate and Lateral Acceleration Sensor (JL4) Page 2347 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 14732 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 6204 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Important: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 12982 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 6258 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Controls Component Viewst Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Page 6203 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 7244 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 11419 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 24424 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Page 2416 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 3171 Page 22588 Power Door Lock Switch: Diagrams Vehicle Access Connector End Views Door Lock Switch - Driver (AU3 -AN3/DL3) Door Lock Switch - Passenger (AU3 -AN3/DL3) Page 6069 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 12836 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 14006 Valve Body Spring and Bore Plug Chart (inch) Page 23880 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 14986 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 9997 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 16071 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 14721 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 9548 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (3) up and over the knock sensor. 4. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 5. Lower the vehicle. Page 5089 Page 8921 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 23939 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Lighting Systems Connector End Views Ambient Light Sensor: Diagrams Lighting Systems Connector End Views Lighting Systems Connector End Views Ambient Light Sensor (C67/C42) Page 7769 Page 442 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 15288 Rear Brake Rotor Replacement (JD9) Rear Brake Rotor Replacement (JD9) Page 566 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 9478 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 3015 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 23182 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 16207 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 14377 Page 16489 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X414 Inline Harness Connector End Views Page 1948 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 14423 6. Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 7. Road test the vehicle and verify that the noise is gone. Note Do Not replace the slip yoke unless the cleaning and lubrication procedure is ineffective. 8. If the vehicle has a repeat concern after lubricating the slip yoke splines, it may be necessary to replace the propeller shaft slip yoke with a new nickel-plated slip yoke. Replace the Propeller Shaft Slip Yoke 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. Important Some U-joints are fastened with nylon injection clips. If so, Do Not reuse the U-joint. Replace with GM P/N 12479126 U-Joint kit. 2. Replace the propeller shaft slip yoke with a new nickel-plated slip yoke. Refer to Propeller Shaft Slip Yoke Replacement in SI. 3. Install the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7094 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 17040 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 12930 Page 17059 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 6616 View of the connector when released from the component. View of another type of Micro 64 connector. Page 1117 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 13699 14. Remove the range selector cable (2) from the transmission range selector lever ball stud. 15. Remove the retainer (1) that secures the cable to the bracket. 16. Depress the tangs and remove the cable from the bracket. 17. Remove the transmission range selector cable from the vehicle. Installation Procedure 1. Install the transmission range selector cable to the vehicle. 2. Ensure that the transmission manual shaft lever is in the mechanical park position. 3. Align and install the range selector cable (2) to the bracket. 4. Install the retainer (1) that secures the cable to the bracket. 5. Install the range selector cable end to the transmission range selector lever ball stud. 6. Install the cable clip on the transfer case, if equipped. Page 22601 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Page 19892 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 548 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Radiator Surge Tank Inlet Hose/Pipe Replacement Coolant Reservoir: Service and Repair Radiator Surge Tank Inlet Hose/Pipe Replacement Radiator Surge Tank Inlet Hose/Pipe Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Reposition the surge tank inlet hose clamp from the radiator. 3. Remove the surge tank inlet hose from the radiator. Page 9169 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 23830 For vehicles repaired under warranty, use the table above. Disclaimer Page 6510 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 23566 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub: Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 7506 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 14570 17. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 18. Remove the 7 valve body checkballs. Important: Some models do not have an outer spring. Note spring usage during removal. 19. Remove the accumulator cover bolts (58, 59). 20. Remove the 1-2 accumulator cover and pin assembly (57). Page 17849 Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (4WD 2500 HD, 3500) Drivetrain and Front Suspension Frame Front Crossmember Replacement (4WD 2500 HD, 3500) Page 13819 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 2689 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 12445 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 11091 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 3220 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 20769 Page 99 For vehicles repaired under warranty use, the table. Disclaimer Page 16170 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 1660 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Entertainment System - DVD Monitor Display Inoperative DVD Player: All Technical Service Bulletins Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Page 15875 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 568 View of the connector when released from the component. View of another type of Micro 64 connector. Service and Repair Oil Change Reminder Lamp: Service and Repair Engine Oil Life System When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it indicates that an oil change is necessary. A CHANGE ENGINE OIL SOON message comes on. See DIC Warnings and Messages. Change the oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if driving under the best conditions, the oil life system might not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. Your dealer/retailer has trained service people who will perform this work using genuine parts and reset the system. It is also important to check the oil regularly and keep it at the proper level. If the system is ever reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change. Remember to reset the oil life system whenever the oil is changed. How to Reset the Engine Oil Life System (From Owner's Manual) The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Whenever the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message coming on, reset the system. Always reset the engine oil life to 100% after every oil change. It will not reset itself. To reset the Engine Oil Life System: 1. Display the OIL LIFE REMAINING on the DIC. If the vehicle does not have DIC buttons, the vehicle must be in P (Park) to access this display. 2. Press and hold the SET/RESET button on the DIC, or the trip odometer reset stem if the vehicle does not have DIC buttons, for more than five seconds. The oil life will change to 100%. If the CHANGE ENGINE OIL SOON message comes back on when the vehicle is started, the Engine Oil Life System has not reset. Repeat the procedure. GM Oil Life System Resetting (From Service Manual) When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL SOON message will come on. Change the engine oil as soon as possible within the next 1 000 km (600 miles). It is possible that, if driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, change the engine oil at 5 000 km (3,000 miles) since last oil change. How to Reset the Engine Oil Life System (From Service Manual) The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Anytime the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message being turned on, reset the system. If the vehicle does not have a Driver Information Center (DIC), do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Fully press and release the accelerator pedal slowly three times within five seconds. 3. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. If the vehicle has a DIC, do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Press the MODE button until the DIC reads OIL LIFE LEFT/HOLD SET TO RESET. 3. Press and hold the SET button until 100 percent is displayed. You will hear three chimes and the CHANGE ENGINE OIL SOON message will go off. 4. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the Page 11996 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (3) up and over the knock sensor. 4. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 5. Lower the vehicle. Page 4106 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 16246 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 12142 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 23112 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: Customer Interest A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Page 1074 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 15191 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, Page 1312 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10417 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 3468 Frame Angle Measurement (Express / Savana Only) ........ Page 3031 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 11043 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 12155 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 7040 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 10473 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 14474 Shift Effort Shift effort will vary among different style transmissions and synchronizer designs. Usually the more heavy duty the transmission, the higher the shift effort because of the increased mass of the components. Shift effort can also be higher in cold weather because the fluid will be thicker. Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder will only increase the chance of rushing past the synchronizer leading to grinding while shifting. Non-Synchronized Gears Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various transmissions, along with all gears in some medium duty transmissions, may be non-synchronized. This means there is not a mechanism to match input and output shaft speeds to allow for a smooth shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind. The grinding can be reduced by coming to a complete stop and pausing for a moment before shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft (driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other methods. If the driver is not able to perform this function properly, there will be gear grinding with each improperly completed shift. Driver training may be required to correct this condition. Clutch brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The clutch brake is intended to only be used while at a stop. Care must be taken to not activate the clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or missed shift. Skip Shift Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models may follow) equipped with the 6-speed manual transmission have a feature referred to as a "skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel economy standards. The conditions for this feature are: engine coolant at normal operating temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to Service Information or the Owner Manual for more details.) Disclaimer Page 12539 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 7900 Page 1910 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 14359 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Page 11684 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 16880 Fuse: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 8077 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 21551 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 11403 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 1066 Page 8214 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 10802 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 13016 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 21549 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 13170 1. Install a NEW seal (2) to the indicator tube. 2. Install the oil level indicator tube (1). 3. Install the transmission. 4. Lower the vehicle. 5. Check the transmission fluid level. 6. Install the transmission oil level indicator. 7. Lock the transmission oil level indicator. Page 17253 Disclaimer Page 12189 Specifications Brake Fluid: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid. Page 15380 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the J 45405. 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. Page 15479 Parking Brake Rear Cable Replacement - Right Side (JH6, JH7) Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the right park brake cable from the equalizer (1). 5. Release the right park brake cable from the frame bracket by compressing the locking tabs on the cable conduit (2) and pulling the cable rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). Page 5316 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 7119 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 13040 12. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. 13. Remove the 3-4 accumulator piston (2). 14. Inspect the 3-4 accumulator spring for cracks. 15. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. 16. Inspect the 3-4 accumulator piston for the following conditions: * Porosity * Cracks * Scoring * Nicks and scratches Installation Procedure Page 14729 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 7802 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 8323 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 8086 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 10997 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 6455 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 13843 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 5198 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Procedures Hydraulic Brake Booster: Procedures Power Brake Booster Leak Inspection Important: The power brake booster may appear wet due to excessive assembly fluid during manufacturing or brake fluid that could have been spilled during system fill. In an effort to prevent unnecessary replacement of the power steering boosters, perform the following power brake booster leak inspection before replacing the power brake booster. 1. Check the power steering system fluid and adjust the level if necessary. Refer to Checking and Adding Power Steering Fluid (With Hydroboost) Checking and Adding Power Steering Fluid (Without Hydroboost). 2. Clean any fluid off all of the following areas: * The power brake booster housing and fittings 3 * The joint between the power brake booster housing and master cylinder 2 * The end cap * The joint between the power brake booster housing and end cap 1 Important: To properly diagnose a leak condition, aid from an assistant may be required. The power brake booster system must be observed while completing this inspection. 3. Start the engine and allow the power steering fluid to reach operating temperature. 4. Allow the engine to idle and slowly apply the brake pedal to run-out, holding until the power steering pump reaches the pressure relief valve setting and hisses. Then maintain this brake pedal force for approximately two seconds longer, then release the brake pedal. 5. Allow the engine to idle with your foot off the brake for fifteen seconds. 6. Repeat steps 4 and 5 four more times. Important: Do not hold the wheel for more than three seconds at full stop, as this will increase the fluid temperature in the pump above operating temperature. 7. With the engine idling, turn the steering wheel from stop to stop four times and hold the wheel at each stop for two seconds. 8. Increase the engine idle speed to approximately 1000 RPM and turn the steering wheel from stop to stop six times at a rate of one turn of the steering wheel approximately every second. Do not hold the wheel at full stop. 9. Allow the engine to idle with your foot off the brake for thirty seconds. 10. With the engine idling, apply the brake pedal to run-out and hold the pedal force at run-out for approximately one second and the release the brake pedal. 11. Repeat steps 7 through 10 four times. 12. Allow the engine to idle for thirty seconds and then turn the engine off. Page 22555 Page 24040 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Non-Adjustable Pedal) Stop Lamp Switch Replacement (Non-Adjustable Pedal) Page 15179 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Rear Wheel Speed Sensor Ring Replacement Tools Required * J 8092 Driver Handle * J 21128 Axle Pinion Oil Seal Installer * J 23690 Bearing Installer * J 2619-01 Slide Hammer * J 45857 Tone Wheel and/or Bearing Remover * J 45860 Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. 3. Remove the rear wheel speed sensor. 4. Remove the rear axle housing cover. 5. Remove the axle shaft. 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J 45857 (1) and the J 2619-01 (2). Installation Procedure 1. Install the wheel speed sensor ring using the J 45860 (1) and the J 8092 (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. Page 24015 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 9063 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 3317 Important: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 3. Mount the tire to the rim. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 15429 Master Cylinder Replacement (JH6, JH7) Master Cylinder Replacement (JH6, JH7) Page 3452 Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Lens Replacement Windshield Outside Moisture Sensor Lens Replacement Page 21617 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 11425 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 7005 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 2975 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 21645 Heated Seat References Page 5008 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Service and Repair Backing Plate: Service and Repair Rear Brake Backing Plate Replacement Page 7803 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13853 Torque Converter Clutch Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 6L50/6L80/6L90 - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Page 4899 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 8204 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure Page 14877 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 14763 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 6528 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 12226 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 23734 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 15325 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes 15. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Page 12624 Shift Solenoid 1 (SS1) Shift Solenoid 2 (SS2) Page 20721 Front Door Panel: Service and Repair Front Side Door Pull Handle Replacement Front Side Door Pull Handle Replacement Page 9893 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 23136 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 23528 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Non-Adjustable Pedal) Stop Lamp Switch Replacement (Non-Adjustable Pedal) Page 1995 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 14874 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Front Seat Adjuster Replacement (Power) Power Seat Motor: Service and Repair Front Seat Adjuster Replacement (Power) Front Seat Adjuster Replacement (Power) Page 10984 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 16777 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 4130 Junction Block - Left I/P X9 Page 12603 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 5407 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 5423 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 16677 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Auxilary Power Outlet - Center Seat (AZ3) 1 - Auxilary Power Outlet - Center Seat (AZ3) Console Components Page 10093 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 12. If equipped with 2-wheel drive (2WD) perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service. 13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (2). 16. Remove the fuel/EVAP line clip nut (1). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Page 15093 Transmission Position Switch/Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft Position Switch Replacement Page 4103 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 21440 Instrument Panel Storage Compartment Replacement Instrument Panel Storage Compartment Replacement Page 23572 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 16682 Page 3719 1. Install the power steering gear outlet pipe (1) to the steering gear (2). 2. Connect the power steering fluid cooler hose (3) and hose clamp to the steering gear (2). 3. Clean any excess fluid from the vehicle and remove the drain pans. 4. Fill and bleed the power steering system. Page 24195 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 22497 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 13615 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 7197 Page 22918 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 9832 Page 21838 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 8661 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 6545 Page 7847 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 17091 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 15386 Page 9185 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 15279 10. Mount a dial indicator, J 45101, or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 11. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 12. Compare the brake rotor assembled LRO to the following specifications: Brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in) Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.25 mm (0.010 in) 13. If the brake rotor assembled LRO is within specifications, proceed to step 18. If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism, refer to Brake Rotor Refinishing. After refinishing the rotor, proceed to step 14. 14. Mount a dial indicator, J 45101, or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 15. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 16. Compare the brake rotor assembled LRO to the following specification: Brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in) Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.25 mm (0.010 in) 17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction. See: Brake Rotor Assembled Lateral Runout Correction 18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. Brake Rotor Surface and Wear Inspection Brake Rotor Surface and Wear Inspection Page 7406 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 6851 Page 2869 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 6335 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 15256 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Page 11778 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 15507 Hydraulic Brake Booster: Removal and Replacement Power Brake Booster Replacement (Non-Adjustable Pedals) Power Brake Booster Replacement (Non-Adjustable Pedals) Page 22202 Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Front Center Seat Back Cushion Latch Upper Cover Replacement (AZ3) Instruments Nav. Radio Clock/Clock Tab Malfunctions Navigation System: Customer Interest Instruments Nav. Radio Clock/Clock Tab Malfunctions Bulletin No.: 08-08-44-002 Date: February 15, 2008 TECHNICAL Subject: Navigation Radio Clock and/or Clock Tab Do Not Appear or Disappears Intermittently (Update Navigation Radio with New Software) Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008 HUMMER H2 with Radio RPO UVB or U3U Condition Some customers may comment that the clock and/or the clock tab does not appear on the navigation screen. Cause This condition may be caused by a software anomaly, which causes the clock and/or clock tab to disappear during the ignition key cycle. Correction DO NOT REPLACE THE NAVIGATION RADIO. Using the Tech 2(R), verify that the vehicle is equipped with one of the following radio part numbers: If the vehicle is not equipped with one of the following radio part numbers, disregard this bulletin. 15882766 15882767 15940102 15940103 25797978 25834072 Update the Navigation Radio's software to correct this condition. This software upgrade will also update some operating characteristics on the Navigation Radio. The following functions or displays may be affected: Inform the customer that stored destinations and radio presets may not be retained during programming. clock font size text color on light colored screens split screen icon to minimize the "Points of Interest" popup and "Exit" popup change driver locked out features when the vehicle is out of "Park" "back" button on street address entry screen for entering street number How to Obtain Nav Software Update Disc (P/N 25956121 - software version 0B92): Software discs are available through the GM Nav Disc Center. Dealers should retain the disc for use in repairing future vehicles. DO NOT give the software disc to the customer. Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 12725 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 16879 Fuse: Locations Right I/P Junction Block Junction Block - Right I/P, Top View Page 8189 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 9878 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 5870 Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 6742 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 16103 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Heated Oxygen and Oxygen Sensor Notice Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice Heated Oxygen and Oxygen Sensor Notice Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Page 19272 Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Extended/Crew Cab) Keyless Entry Antenna Replacement (Extended/Crew Cab) Page 22504 Page 15109 Transmission Speed Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Input and Output Speed Sensor Replacement Page 14859 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Locations Air Bag Deactivation Switch: Locations SIR Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 21030 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Crew Cab) Page 2570 Transmission Position Switch/Sensor: Service and Repair Allison - Automatic Transmission Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Page 2875 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 5372 Page 3287 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Page 2621 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Procedures Brake Master Cylinder: Procedures Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Caution: Refer to Brake Fluid Irritant Caution. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. Page 16747 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Disconnect the engine wiring harness electrical connector (4) from the crankshaft position (CKP) sensor. Page 24601 Windshield Washer Pump: Service and Repair Washer Pump Replacement (Silverado) Page 6711 Vehicle Zoning Strategy Truck Zoning Page 9576 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 17503 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 3099 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Page 10846 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 20983 Rear Door Panel: By Symptom Technical Service Bulletin # 07-08-64-004 Date: 070228 Body - Water Leaks Into Rear Footwell Area Bulletin No.: 07-08-64-004 Date: February 28, 2007 TECHNICAL Subject: Wet or Stained Carpeting in Rear Footwell After Heavy Rainfall or Car Wash (Replace Water Deflector) Models: 2007 Chevrolet Silverado Extended Cab (New Body Style) 2007 GMC Sierra Extended Cab (New Body Style) Condition Some customers may comment on wet or stained carpeting in the rear footwell after a very heavy rainfall or high pressure car wash. Cause This condition may be caused by a void in the loft area around the map pocket on the TIAS water protector (water deflector) inside the door trim. This loft area normally creates an interference condition, causing the adhesive bead to wet out and seal off the water. When a void is present, water intrusion may occur. Correction Carefully remove the interior rear side door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9 or SLT) in SI. Inspect the water deflector for a missing loft. Refer to the illustration above for an example of a correct loft (1) and a missing loft (2). If the loft is missing, replace the water deflector with a new service part. Inspect the opposite side door and replace the opposite side water deflector if necessary. Refer to Rear Side Door Water Deflector Replacement in SI. Parts Information Warranty Information Side Window Air Outlet Replacement Air Register: Service and Repair Side Window Air Outlet Replacement Side Window Air Outlet Replacement Page 1036 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 12657 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Locations Crankshaft Position Sensor: Locations Engine Controls Component Views Right Side of Engine 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 10499 1. Lubricate the NEW injector O-ring seals with clean engine oil. 2. Install the fuel injector (2) into the fuel meter body injector socket. Notice: Refer to Fastener Notice. 3. Install the injector retainer (3) and the injector retainer lock nuts (4). Tighten the nuts to 3 N.m (27 lb in). 4. Install the fuel meter body. Page 22066 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 881 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module 7 - Fuse Block - I/P Page 6339 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 24265 Page 8144 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 21845 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 16758 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 18293 Cabin Temperature Sensor / Switch: Diagrams HVAC Connector End Views Inside Air Temperature Sensor - Front Page 18199 Mode Actuator Recirculation Actuator Page 22961 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 178 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 16952 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 4697 9. Remove the engine wiring harness ground nut and ground wire (1) from the rear of the right cylinder head. 10. Remove the stud (1) holding the engine wiring harness bracket. 11. Reposition the engine wiring harness with the bracket aside. Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Page 21629 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 14072 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: * M6 X 1.0 X 65.0 (1) * M6 X 1.0 X 54.4 (2) * M6 X 1.0 X 47.5 (3) * M6 X 1.0 X 35.0 (4) * M8 X 1.0 X 20.0 (5) * M6 X 1.0 X 12.0 (6) * M6 X 1.0 X 18.0 (7) A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 10165 4. Loosen the air cleaner housing screws. 5. Lift up the air cleaner housing cover. 6. Remove the air filter element. Installation Procedure 1. Insert the NEW air filter element. 2. Install the air cleaner housing cover. Notice: Refer to Fastener Notice. 3. Tighten the air cleaner housing screws. Tighten the screws to 3 N.m (27 lb in). Page 4025 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: All Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 10654 4. Inspect for fuel leaks. Page 11250 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 3190 1 - Lower Radiator Support 2 - Inflatable Restraint Front Sensor Under the Front Seats Page 23107 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 2341 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 3367 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Page 22507 Heated Seat Element - Passenger Back Page 16527 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 13834 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 10804 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 481 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 16166 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 962 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 5102 Page 23583 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 7303 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 6729 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 1571 Page 14617 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Notice: Refer to Fastener Notice. 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 N.m (92 lb in). 5. Install the control valve assembly. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 7423 Page 12878 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 21555 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 10018 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 927 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 975 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 2152 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure Page 11129 Page 19825 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components Refer to SIR Identification Views. There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. Remove the tire from the wheel. Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 3. Remove the tire pressure sensor nut. 4. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Page 5137 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 8957 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 11624 4. Position the knock sensor heat shield to the engine block and install the bolt. Tighten the bolt to 10 N.m (89 lb in). 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. Page 13005 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 22445 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 22919 Cruise Control: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 11385 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 11040 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 4935 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14840 Page 15341 Rear Brake Caliper Replacement (JH6, JH7) Rear Brake Caliper Replacement (JH6, JH7) Page 16981 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10855 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 24699 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2522 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 20514 Body Control Module: Locations Data Communication Component Views Behind the I/P 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) (Export) Below the I/P Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Caution: Refer to Brake Dust Caution. 1. Inspect the brake caliper housing for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seals for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seals and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. Insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Page 6942 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 1932 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 22458 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 2687 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 19852 minutes. After the system restarts, press the "EJECT" soft key to eject and remove the software update disc. Dealers should retain the software update disc for their use. Load the map DVD into the same slot located behind the display screen, DO NOT put in the top slot. Press the "CLOSE" soft key. Press the "OK" soft key. Press the "MENU" hard key. The clock will not be displayed until it is confirmed by completing step 16. Turn the engine OFF, open and close the drivers door. Wait for 10 minutes. Due to the load time of the system, there may be a short delay before the "Map Screen" appears. Restart the engine. After the map screen is displayed, verify that the clock is visible and touch the map screen to confirm that it can be scrolled. If the clock does not appear, repeat programming. The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. Verify that the destination search area is properly displayed. Press the "DESTINATION" hard key. Press "CHANGE SEARCH AREA" soft key. Select the correct area for the vehicle's location. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12065 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 988 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 1564 Wheel Speed Sensor (WSS) - Right Front (JH6/JH7) Wheel Speed Sensor (WSS) - Right Rear (JL4) Wheel Speed Sensor (WSS) - Right Rear (JL4) Wheel Speed Sensor (WSS) - Right Rear (JL4) Locations Hood Sensor/Switch (For Alarm): Locations Immobilizer Component Views Near the Hood Latch 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor - ISRVM Page 2369 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 21417 The four outer tabs will not allow the cup liner to seat properly into the rear cupholder assembly causing a poor fit and a gap. Carefully cut off the two front outer tabs (1), referring to the graphic above, and cut off the two back outer tabs. Install the updated rear console cup liner as shown above. Close the console cupholder assembly. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6062 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 18334 GM Engineering is seeing an increase in HVAC control head and actuator warranty where the component is fully functional when received. The root cause of the failure is intermittent wiring connections at the right hand BEC. Specifically, poor terminal tension of the 5V reference or Low Reference terminals in the X4 connector. Refer to the table. After the fault is removed. the actuators recover once commanded. Correction DO NOT REPLACE THE CONTROL HEAD. Use the following information to diagnose this condition: Locations Fuel Tank Pressure Sensor: Locations Engine Controls Component Views Near the Fuel Tank 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (- Diesel) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Line Pressure Sensor (-LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly - Front (Gas) Page 1795 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 5835 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 3095 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11245 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 10203 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 7957 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 19346 Parking Assist Control Module: Locations Object Detection Component Views Under the Front Seats 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Page 15275 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Important: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. See: Brake Rotor Thickness Measurement * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Brake Rotor Assembled Lateral Runout Measurement Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * Brake Rotor Assembled Lateral Runout Correction - Indexing The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. * Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Brake Rotor Assembled Lateral Runout Correction - Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Tools Required * J 39544-KIT Torque-Limiting Socket Set, or equivalent * J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution. Important: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. See: Brake Rotor Thickness Measurement * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Brake Rotor Assembled Lateral Runout Measurement Page 6576 Page 14061 Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly Page 9684 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1) from the HO2S pigtail electrical connector. 4. Remove the HO2S pigtail electrical connector clip (2) from the frame. 5. Remove the HO2S (4). Page 16333 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 11913 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 1267 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 7048 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 14120 - The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. - When releasing the park brake pedal, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. If a condition is suspected/found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202) or at any of these areas of concern then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Visually inspect the IP harness for damage at the park brake pedal assembly. Refer to potential damage points shown in the photos at the side and rear of the park brake assembly. Note that damage may be hidden from view. The harness may be turned away from you, or covered by electrical tape. 4. Operate the park brake release lever. Observe the moving part at the end of the park brake release cable as it may contact and damage the IP harness. Inspect the IP harness at this point. Note that the damage may be hidden from view by electrical tape. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. If the harness is still in contact with a sharp edge or point of the park brake assembly, route it away from the contact point and secure it with tie straps. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Page 8083 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 3920 View of the connector when released from the component. View of another type of Micro 64 connector. Page 9902 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 17986 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 3464 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 19124 Page 11079 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 11693 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 16893 Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Label Page 6115 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 8283 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 7972 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 15395 Front Brake Hose Replacement (JH6, JH7) Front Brake Hose Replacement (JH6, JH7) Page 6114 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 16919 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 489 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 1458 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 22319 Page 21312 Disclaimer Page 13786 View of the connector when released from the component. View of another type of Micro 64 connector. Page 6379 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Reluctor Ring Replacement Crankshaft Position Sensor Reluctor Ring Replacement Tools Required j 5590 Rear Pinion Bearing Race Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position (CKP) sensor reluctor ring. Installation Procedure Page 13764 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 7837 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 2484 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 3139 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 16171 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 21390 Console: Service and Repair Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Page 9108 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Diagrams Keyless Entry Receiver: Diagrams Remote Function Connector End Views Remote Control Door Lock Receiver (RCDLR) Page 21124 Page 13414 1. Remove the torque converter from the transmission. 2. Obtain J 24171-A and install the tip (3) with a 90 degree hook onto the end of the slide-hammer (1). 3. Position the 90 degree hook behind the rear face of the seal outer case (2). Remove the torque converter seal using the slide-hammer. 4. Inspect the seal bore for scratches. Remove any scratches in the seal bore using crocus cloth. Installation Procedure 1. Install the new seal (2) onto the J 43772. Position the seal so the seal lip is outward and the face of the steel case is against the driving face (1) on the tool. 2. Slide J 43772 over the turbine shaft and the stator shaft until the seal starts into the seal bore. Strike the J 43772 with a mallet (1) to drive the seal into the seal bore. The seal is installed correctly when the shoulder of the J 43772 squarely contacts the outer surface of the oil pump. 3. Install the torque converter into the transmission. Torque Converter Housing Bolt Seal Replacement Torque Converter Housing Bolt Seal Replacement Removal Procedure Page 11811 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 12732 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 7208 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 1830 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 12478 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 2922 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: Customer Interest Park Assist System - Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components Refer to SIR Identification Views. There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. Page 11363 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 15861 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 10586 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 6294 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 13633 Tighten the bolt to 11 N.m (97 lb in). 6. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 9. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 22757 A removable insert, shown above, was added to the outer groove of the upper side rail clamp to help prevent improper positioning from unintentionally occurring. Check that the clamps are properly installed using the correct groove in the upper side rail clamp. Correct positioning is detailed in the illustration above. Cause #2 The condition may be caused by the tonneau bows not falling into proper position when the tonneau cover is rolled out. This cause would indicate that repositioning on an upper side rail clamp is needed. Correction #2 Note the position of the bows and use the appropriate repair below: - If bows do not fit between the side rails and additional clearance is required, remove the clamp nearest the interference. Remove the orange strip to allow access to the outer groove of the upper clamp. Reinstall the clamp, using the outer groove of the upper clamp. - If bows are too loose, adjust the clamp nearest the bow with excessive clearance to the inner groove of the upper clamp. Cause #3 This condition may be caused by a misalignment of the tonneau side rails and/or improper adjustment of the forward tension screws. The graphic above shows a misalignment of the tonneau side rail (1) to the front of the pickup box (2). Correction #3 1. Verify that the tonneau side rails are aligned with the front of the pickup box as shown above. 2. Ensure that the side rails are aligned with each other in the same fore/aft position (1) on the vehicle. Note Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Module Replacement Page 12579 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Interior - Front Power Seat Adjust/Memory Inoperative Power Seat Switch: All Technical Service Bulletins Interior - Front Power Seat Adjust/Memory Inoperative Bulletin No.: 06-08-50-012 Date: October 06, 2006 TECHNICAL Subject: Front Driver or Passenger Power Seat Adjust Functions Inoperative and/or Driver Seat Memory Inoperative (Check Power Seat Switch Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (New Style), Suburban, Tahoe 2007 GMC Sierra (New Style), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the front driver or passenger power seat adjust functions are inoperative. They may also comment that the driver seat memory is inoperative. Cause The cause of this condition may be due to the power seat switch connector not being fully seated. Correction Remove the front seat cushion outer trim panel following the replacement procedure in SI. Verify that the power seat switch connector is fully seated. Reseat the connector and test the seat functions. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 21595 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 3946 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 6525 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 12083 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 6315 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 10737 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 5288 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 16451 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6) Page 24180 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 2589 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Page 10429 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 8339 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 15306 Brake Drum: Testing and Inspection Brake Drum Surface and Wear Inspection Brake Drum Surface and Wear Inspection Tools Required j 8001 Dial Indicator Set, or equivalent Caution: Refer to Brake Dust Caution. 1. With the brake drum removed, clean the braking (friction) surface of the brake drum with denatured alcohol or an equivalent approved brake cleaner. 2. Inspect the braking surface of the brake drum for the following braking surface conditions: * Heavy rust and/or pitting-Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the drum. * Cracks and/or heat spots * Excessive blueing discoloration * Missing balance weights 3. If the braking surface of the brake drum exhibits 1 or more of the braking surface conditions, the drum requires refinishing or replacement. 4. Using a brake drum micrometer calibrated in thousands of an inch, measure and record any grooves present on the drum braking surface. Ensure that the measurements are only taken within the brake shoe lining contact area. 5. Compare the groove, scoring, depth recorded to the following specification: Brake drum maximum allowable scoring 1.5 mm (0.06 in). 6. If the brake drum scoring depth exceeds the specification, or if an excessive amount of scoring is present, the drum requires refinishing or replacement. 7. Mount the brake drum on a brake lathe. 8. Mount a dial indicator, J 8001 or equivalent, and position the indicator button so it contacts the braking surface of the brake drum at a 90 degree angle, approximately 19 mm (0.75 in) from the drum's outer edge. 9. Measure and record the radial runout of the brake drum. 1. Rotate the drum until the lowest reading is displayed on the indicator dial, then zero the dial. 2. Rotate the drum until the highest reading is displayed on the dial. 10. Compare the radial runout of the brake drum to the following specification: Brake drum maximum allowable radial runout 0.06 mm (0.0024 in). 11. If the brake drum radial runout exceeds the specification, the drum requires refinishing or replacement. Page 10616 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 23633 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 5297 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 6451 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 2084 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 14915 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 7758 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module 7 - Fuse Block - I/P Page 5952 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20668 Driver/Vehicle Information Display: Description and Operation Driver Information Center (DIC) Description and Operation The driver information center (DIC) displays the DIC WOW for 5 seconds when it first powers up. If enabled through Personalization, the DIC then returns to the last display status before no power condition. There are 4 switch functions for the DIC. * Personalization * Set/Reset * Trip/Fuel * Vehicle Info Trip/Fuel The Trip/Fuel switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Trip/Fuel switch * Accell Rate * Average Fuel Economy (AFE) * Average Vehicle Speed (AVE) * Fuel Range * Fuel Used * Instantaneous Fuel Economy (IFE)/ Displacement on Demand (DOD) * Maximum Speed * Odometer * Trans Temp * Trip A * Trip B * Trip Time Vehicle Info The Vehicle Info switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Vehicle Info switch. * Blank Display * English/Metric Units * Key Fob Programming Menu * Left Front Tire Pressure * Left Rear Tire Pressure * Oil Life Index (OLI) * Right Front Tire Pressure * Right Rear Tire Pressure * Tire Programming Menu Personalization The Personalization switch is used to set personalization features for both the vehicle and the driver. Many of the parameters in the Trip/Fuel menu and the Vehicle Info menu can be programmed through the Personalization switch. In addition to the parameters in the Trip/Fuel and Vehicle Info menus, the following features can also be programmed. * Approach Lighting * Automatic Door Lock * Automatic Door Unlock * Chime Volume * Delayed Door Lock * Display Language * Easy Exit Seat * Exit Lighting * Memory Seat Recall * Remote Door Lock * Remote Door Unlock * Remote Start Page 276 Page 2326 Page 14733 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 251 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 1076 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 20686 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13566 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 10920 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 6L50/6L80/6L90 - Automatic Transmission Transmission Pressure Test Port: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Fluid Pressure Test Hole Plug Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Clean the surrounding area of the oil pressure test plug. 3. Remove the oil pressure test plug. Installation Procedure Notice: Refer to Fastener Notice. Page 24468 Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Lens Replacement Windshield Outside Moisture Sensor Lens Replacement Electrical - Battery Goes Dead Overnight Body Control Module: Customer Interest Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 17031 Page 16418 X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Page 8296 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 6061 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 14679 Pressure Regulating Solenoid: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control (PC) Solenoid Valve, Wiring Harness Side Page 17216 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Page 9577 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 17176 Fuse Block - Underhood X5 (Pin A1 To K3) Page 3663 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 10287 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Page 11973 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9433 Page 3336 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten the bolts in the sequence shown to 11 N.m (97 lb in). 15. Ensure that the manual detent spring is aligned properly with the detent lever. OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 12260 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 13823 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 8625 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 16179 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 7017 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 17064 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 15023 5. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 6. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 7. Remove the TCC solenoid bolts. 8. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 9. Reposition the harness to the side of the transmission case. 10. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 11. Remove the transmission fluid pressure switch. Diagrams Shifter A/T: Diagrams Automatic Transmission Related Connector End Views Automatic Transmission Shift Lever 4-Way Connector Page 3438 Sliding Rear Window - Switch (A48) Locations Parking Brake Warning Switch: Locations Hydraulic Brake Component Views 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Page 13432 5. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 6. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 7. Remove the TCC solenoid bolts. 8. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 9. Reposition the harness to the side of the transmission case. 10. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 11. Remove the transmission fluid pressure switch. Page 3178 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Reposition the knock sensor sleeve (3) down, away from the knock sensor. 4. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. Page 6121 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 15027 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). Tighten the bolts to 10 N.m (89 lb in). Ball Check Valves 5. Install the 7 checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Page 23169 minutes. After the system restarts, press the "EJECT" soft key to eject and remove the software update disc. Dealers should retain the software update disc for their use. Load the map DVD into the same slot located behind the display screen, DO NOT put in the top slot. Press the "CLOSE" soft key. Press the "OK" soft key. Press the "MENU" hard key. The clock will not be displayed until it is confirmed by completing step 16. Turn the engine OFF, open and close the drivers door. Wait for 10 minutes. Due to the load time of the system, there may be a short delay before the "Map Screen" appears. Restart the engine. After the map screen is displayed, verify that the clock is visible and touch the map screen to confirm that it can be scrolled. If the clock does not appear, repeat programming. The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. Verify that the destination search area is properly displayed. Press the "DESTINATION" hard key. Press "CHANGE SEARCH AREA" soft key. Select the correct area for the vehicle's location. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12760 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 16309 Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Page 18602 Control Module HVAC: Locations HVAC - Manual HVAC Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 11087 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 16042 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 10607 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 467 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 24177 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 5195 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 21774 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Page 11325 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 3395 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 16045 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 10983 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 11330 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 5419 View of the connector when released from the component. View of another type of Micro 64 connector. Page 7962 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 18606 Page 20230 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 6229 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 6388 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 3763 Fluid - A/T: Testing and Inspection 4L60-E/4L65-E/4L70-E Transmission Fluid Checking Procedure Transmission Fluid Check This procedure checks the transmission fluid level, as well as the condition of the fluid itself. Notice: Always use the proper automatic transmission fluid listed. Using incorrect automatic transmission fluid may damage the vehicle. Before checking the fluid level, perform the following: 1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then, move the shift lever back to PARK (P). 4. Allow the engine to idle 500-800 RPM for at least 1 minute. Slowly release the brake pedal. 5. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center (DIC) or a scan tool. 6. Using the TFT reading, determine and perform the appropriate check procedure. If the TFT reading is not within the required temperature ranges, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. Cold Check Procedure Important: Use the cold check procedure only as a reference to determine if the transmission has enough fluid to be operated safely until a hot check procedure can be made. The hot check procedure is the most accurate method to check the fluid level. Perform the hot check procedure at the first opportunity. Use this cold check procedure to check fluid level when the TFT is between 27-32°C (80-90°F). 1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on the passenger's side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick tube all the way, wait three seconds and then pull it back out again. Important: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Keep the dipstick pointing down and check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection in this procedure. 6. If the fluid level is below the COLD check line, add only enough fluid as necessary to bring the level into the COLD line. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. 7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. 8. Perform a hot check at the first opportunity after the transmission reaches a normal operating temperature between 82-93°C (180-200°F). Hot Check Procedure Important: Use this procedure to check the transmission fluid level when the TFT is between 82-93°C (180-200°F). The hot check procedure is the most accurate method to check the fluid level. The hot check should be performed at the first opportunity in order to verify the cold check. The fluid level rises as fluid temperature increases, so it is important to ensure the transmission temperature is within range. 1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on the passenger side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick tube all the way, wait three seconds and then pull it back out. Important: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Keep the dipstick tip pointing down and check both sides of the dipstick. Read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection. 6. A safe operating fluid level is within the HOT crosshatch band on the dipstick. If the fluid level is not within the HOT band, and the transmission temperature is between 82-93°C (180-200°F), add or drain fluid as necessary to bring the level into the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band. Important: To assist in reaching the correct temperature range of 82-93°C (180-200°F), drive the vehicle in second gear at no more than 65 mph until the desired temperature is reached. Page 2440 Tighten the sensor to 42 N.m (31 lb ft). 3. If vehicle is a 4WD perform the following steps otherwise proceed to step 7. 4. Install the HO2S pigtail electrical connector clip (9) to the fuel line bracket. 5. Connect the engine wiring harness electrical connector (7) to the HO2S pigtail electrical connector (8). 6. Connect the CPA retainer. 7. If vehicle is a 2WD perform the following steps, connect the HO2S pigtail electrical connector (7) to the engine wiring harness electrical connector (6). 8. Connect the CPA retainer. 9. Lower the vehicle. Page 6924 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 7087 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 24751 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 7818 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 7225 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 5300 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 23109 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4702 12. Install a NEW O-ring seal to the fuel meter body. 13. Install a NEW upper intake manifold gasket. 14. Install the intake manifold - upper. 15. If reusing the old throttle body/intake manifold studs, apply threadlock to the threads. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 16. Install the front two throttle body studs. 17. Install the intake manifold - upper studs. Tighten the studs to 9 N.m (80 lb in). 18. Connect the power brake booster vacuum hose to the vacuum fitting. 19. Install the PCV valve hose to the valve cover and rocker cover. Page 16944 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 15221 Page 9580 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 2042 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 948 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 17259 The concern must be current before diagnosis can be performed. Review and print the following SI documents - Electrical Center Identification Views, for use during diagnosis: - Junction Block - Right I/P, Top View - Junction Block - Right I/P X4 - Junction Block - Right I/P X5 Locate the Junction Block - Right Side IP on the vehicle. For the appropriate actuator, measure the following signals for voltage/resistance from the BACK of the X4 or X5 connector and record the following: DO NOT unplug the X4/X5 connector. Turn Ignition On, A/C Blower Full, if possible - mode on "panel" and Temp to "cold." Once the fault is removed, the actuator will stay in default position until commanded to a new position. Change commanded position regularly to see if the issue is still current. Continue to monitor door positions (feedback) on Tech2 to see if it changes during circuit testing. - Ignition Voltage - 12V - Door Control Signal - 2.5V when stationary, OV when commanded toward "cold" or "panel", 5V when commanded toward "hot" or "defrost" - Low Reference - less than 40 ohm with ignition on. Less than 10 ohm with ignition off - Door Position Signal - measure voltage - 5 Volt Reference - 5V If any signals do not display the correct value or if the issue is corrected during testing, pull the connector and check the terminal for poor tension (use the appropriate terminal tool). Replace or repair the terminal if poor tension is found. If all signals are correct at RH BEC, reconfirm the customer's comments. If the condition is not present, no further repairs are necessary. If the condition is still present, recheck the actuator connector 5 volt reference circuit, pin drag test and repair connector/pin as necessary. Warranty Information For vehicles repaired under Enqineerinq direction, use the table. Page 19507 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Page 3040 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 6694 Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (4). Tighten the sensor to 42 N.m (31 lb ft). 3. Install the HO2S pigtail electrical connector clip (2) to the frame. Page 10047 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 17866 Page 13813 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 3351 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 2817 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 13611 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9217 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 16579 For vehicles repaired under warranty, use the table. Disclaimer Page 12617 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 22143 Seat Recline Motor - Passenger (AN3) Page 2660 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9291 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 11412 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 14159 3. For the 9.5/9.5LD and the 10.5 inch axles, install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 4. For the 11.5 inch axle, install the seal and the fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 5. Lower the vehicle. Page 2231 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 1863 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 14748 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 4064 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16052 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 3921 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 9481 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 15992 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 2371 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 9276 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 22368 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 18909 Air Bag Control Module: Locations SIR Component Views Under the Front Seats 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Page 1078 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 4403 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Page 2675 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Body - Soft Tonneau Cover Appears Loose/Won't Latch Truck Bed Cover Latch: All Technical Service Bulletins Body - Soft Tonneau Cover Appears Loose/Won't Latch TECHNICAL Bulletin No.: 09-08-66-004A Date: January 04, 2011 Subject: Roll Up Soft Tonneau Cover Appears Loose or Latch Not Functioning Properly (Adjust Upper Side Rail Clamps and/or Rails and/or Replace Rear Latch) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Attention: This bulletin only applies to vehicles with tonneau part numbers 19213900, 19213901, 19213902, 19213903, 19213904 and 19213905. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the roll up soft tonneau cover is too loose, or that the tonneau cover latch is disengaging and not staying closed. Two improvements have been implemented since the original release of the tonneau cover. Be sure that the tonneau cover meets the criteria of the items below. Cause #1 The condition may be caused by improper installation of one or more of the upper side rail clamps. Using the outer groove (1) when a molded bed rail protector IS NOT installed may cause a gap (2) between the pad and pickup box. This may also prevent proper latch retention. Correction #1 Note Page 2880 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 24707 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 3032 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 10729 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 13168 4. Install a NEW fill tube seal. 5. Install the fill tube. Ensure that the fill tube bracket is positioned properly on the studs. Notice: Refer to Fastener Notice. 6. Install the fill tube nuts. Tighten the nuts to 18 N.m (13 lb ft). 7. Install the heat shield. 8. Lower the vehicle. 9. Fill the transmission to the proper level with approved fluid. Page 6468 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 20992 Page 8044 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 11668 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 21560 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 23068 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 18603 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 21670 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Page 17755 Steering Angle Sensor: Removal and Replacement Steering Wheel Position Sensor Replacement Page 14692 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. 6. Enable the SIR system. Page 5506 Important: After assembly, the hose clamp tangs (water pump end) must point forward and the upper tang should be level with the outside diameter of the water pump inlet hose. 5. Install the water pump inlet hose. 6. Position the water pump inlet hose clamps. 7. Install the radiator outlet hose to the water pump. 8. Install the radiator outlet hose to the surge tank. 9. Position the radiator outlet hose clamps at the surge tank and water pump. 10. Install the drive belt. 11. Install the air cleaner outlet duct. 12. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 13. Inspect the cooling system for leaks. Page 18090 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 16010 Page 12897 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 13912 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Page 13562 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 491 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 4987 Page 11031 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 23858 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 16690 Page 8300 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 10385 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 4938 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 12030 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 17362 X211 Instrument Panel Harness (Y91) Or I/P Extension Harness (-Y91) To Console Harness (Y91/UQA/D07) (Pin C7 To D8) X212 Inline Harness Connector End Views X212 Instrument Panel Harness to Instrument Panel Extension Harness (-Y91) Page 1949 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 14101 6. Lower the transmission sufficiently to provide access to the engine wiring harness where it routes from the engine intake manifold to the transmission bell housing as shown. 7. Release the wiring harness conduit from the retainers that secure it to the transmission and/or transfer case. Note IT WILL be necessary to extract the wiring harness from the protective conduit if chafing IS NOT observed on exposed wiring. 8. Examine the harness for wiring that may be exposed outside of the conduit. Inspect ALL areas for chafing as shown. If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 9. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 10. Raise the transmission as needed to install the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. 11. Lower the vehicle. 12. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 13. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Engine Intake Manifold 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. Audio System - Static/Ignition Noise on AM Band Ignition Cable: All Technical Service Bulletins Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Page 17940 Torsion Bar: Service and Repair Torsion Bars Bushing Replacement Torsion Bars Bushing Replacement Removal Procedure Important: This procedure requires the removal of both torsion bars. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the torsion bars. 3. Remove the bushing from the bracket utilizing a bushing driver or the equivalent. Installation Procedure 1. Install the bushing to the bracket utilizing a bushing driver or the equivalent. 2. Install the torsion bars. 3. Remove the safety stands. 4. Lower the vehicle. 5. Measure the Z height. 6. Turn the adjustment bolt clockwise to increase the Z height and counterclockwise to lower the Z height. Page 21202 Page 17341 X110 Inline Harness Connector End Views X110 Engine Harness (-Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF/NQG/NQH/NP2) Page 499 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16231 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Stop Lamp Switch Replacement (Adjustable Pedal) Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Adjustable Pedal) Stop Lamp Switch Replacement (Adjustable Pedal) Page 4967 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 7157 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: All Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 10399 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12227 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 12742 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 2035 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 24153 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 10906 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 21669 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Page 255 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 22305 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Page 13672 9. Release the white cover (1). 10. Verify the white cover (1) conceals the natural colored lock (2). Page 9990 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 9821 Vehicle Speed Sensor: Locations Power Take-Off Power Take-Off (PTO) Component Views Front Frame Rail 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor 4 - Automatic Transmission Input Shaft Speed (AT ISS) Sensor 5 - Automatic Transmission 6 - Vehicle Speed Sensor (VSS) 7 - X124 8 - Power Take Off (PTO) Module 9 - X175 Page 23948 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 8166 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Resonator Replacement Removal Procedure 1. Disconnect the positive crankcase ventilation (PCV) hose (1) from the air cleaner outlet resonator. 2. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 3. Loosen the air cleaner outlet resonator clamp (2) at the throttle body. 4. Remove the air cleaner outlet resonator from the throttle body and the MAF/IAT sensor. Installation Procedure Page 18745 Air Bag Control Module: Locations SIR Component Views Under the Front Seats 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Page 11417 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 6007 Ignition Control Module: Diagrams Engine Controls Connector End Views Ignition Control Module (ICM) 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Shift Solenoid Valve State and Gear Ratio Page 4117 Fuse Block - I/P X3 Page 22294 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 17393 X700 - X799 Inline Harness Connector End Views X700 Left Rear Door Harness to Body Harness (Extended Cab) Page 7778 Page 18317 7. Install the lower bolts to the hood latch support bracket. Tighten the bolts to 9 N.m (80 lb in). 8. Install the radiator support. Access the bolts (1) from the rear of the upper radiator support. Refer to Radiator Support Replacement. Tighten the nut to 16 N.m (12 lb ft). 9. Install radiator support bracket bolts (1). 10. Install the fascia. 11. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 12. Leak test the fittings of the component using the J 39400-A. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 12105 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 21378 replacement set faxed or e-mailed to your dealership. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. - In the USA, call 1-800-955-8591. - In Canada, call 1-800-977-4145. Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Front Floor Panel Carpet Replacement (Crew Cab) Front Floor Panel Carpet Replacement (Crew Cab) Page 877 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 2917 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 11869 Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face the engine front cover. Failure to do so will damage the front cover and the reluctor ring. 1. Install the CKP sensor reluctor ring. 1. Align the keyway on the CKP sensor reluctor ring with the key in the crankshaft. 2. Using J 5590, push the CKP sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. 2. Install the engine front cover. Page 18743 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 9239 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion A/C - Does Not Cool/Can't Change Mode/DTC's Set Control Assembly: All Technical Service Bulletins A/C - Does Not Cool/Can't Change Mode/DTC's Set Bulletin No.: 07-01-38-009B Date: November 28, 2007 TECHNICAL Subject: EI07264 - Manual HVAC, Temperature or Mode Actuator Performance, A/C Does Not Cool, Unable to Change Mode, DTC B0228, B0413, B0423, B0433, B3779, B3782 (Diagnose for Intermittent Wiring Connection at RH BEC) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Extended and Crew Cab Models Only with Manual Temperature Control HVAC System (RPO C67) Supercede: This bulletin is being revised to end the need for engineering information and to provide diagnostic procedures to accurately diagnose this condition. Please discard Corporate Bulletin Number 07-01-38-009A (Section 01 - HVAC). Condition This concern only applies to Extended or Crew cab vehicles. If the customer did not bring their vehicle in for this concern, do no proceed with this bulletin. Some customers may comment that the A/C blows hot air or is inoperative. They may also comment that they are unable to change the temperature or HVAC mode of the vehicle. Under these conditions, the actuator has moved to a default position. Refer to the table. Cause Page 7442 pressure should stabilize and remain constant. 1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 3. Remove the J 37287 and CH-48027. 4. Operate the vehicle within the conditions of the customers concern while monitoring the fuel trim and O2 parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 5. If the fuel system components test normal, refer to Symptoms - Computers and Control Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Fuel Injector Replacement * Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Page 14664 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 2764 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 11064 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 17325 X305 Body Harness to Passenger Seat Harness (-AN3) Page 3942 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 2330 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 8699 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 11049 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 6778 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 1041 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 1127 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 15940 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 17133 Fuse Block - I/P X1 Page 22210 Page 16078 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 16475 Page 20950 Rear Door Latch: By Symptom Technical Service Bulletin # 05-08-64-002B Date: 060403 Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: Page 1820 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 6496 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 22499 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 10263 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 3727 Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Remove the engine shield. 2. Place drain pans under the vehicle as needed. 3. Remove as much power steering fluid from the power steering fluid reservoir as possible. Notice: Refer to Power Steering Hose Disconnected Notice. 4. Disconnect the power brake booster inlet hose from the power steering pump (3). 5. Disconnect the power brake booster inlet hose (1) from the power brake booster (2). 6. Remove the power brake booster inlet hose (1) from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice. 1. Install the power brake booster inlet hose (1) to the vehicle. Notice: Refer to Fastener Notice. Important: Start both power brake booster inlet hose fittings by hand before finalizing torques. 2. Connect the power brake booster inlet hose (1) to the power brake booster (2). Tighten the fitting to 32 N.m (24 lb ft). 3. Connect the power brake booster inlet hose (1) to the power steering pump (3). Tighten the fitting to 32 N.m (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Install the engine shield. 6. Fill and bleed the power steering system. Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Page 5418 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Locations Air Flow Meter/Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 15764 9. Ensure the junction block retainers are in the open position (1). 10. Position and align the junction block to the 4 bracket pivots (2), once the pivots are engaged, push the retainer down into the locked position (3). 11. Install the under hood junction block cover. 12. Connect the negative battery cable. Page 9703 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 9883 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 16597 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 2829 Page 19418 For vehicles repaired under warranty, use the table. Disclaimer Page 6172 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 3661 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 10084 1. Position and install the EVAP canister vent solenoid to the vehicle. 2. Slide the EVAP canister vent solenoid onto the bracket towards the driver side of the vehicle. 3. Ensure that the retainer (1) is engaged, securing the EVAP canister vent solenoid. Page 3762 Fluid Inspection Important: Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition. High temperature causes the transmission fluid to be discolored or to have a strong odor. Local conditions, severity of operation, or duty cycle may require more or less frequent fluid or filter change intervals. 1. Examine the drained fluid for evidence of dirt. Important: Cooler water may be contaminated by engine oil if an engine oil cooler is present; be sure to locate the correct source of cooler water contamination. 2. Examine the drained fluid for evidence of water. Obvious water contamination of the transmission fluid or transmission fluid in the cooling water from the heat exchanger indicates a leak between the water and fluid areas of the cooler. Inspect and pressure test the cooler to confirm the leak. Replace leaking coolers. Notice: Engine coolant in the transmission hydraulic system requires immediate action. Failure to clean or replace all contaminated components may result in premature transmission failure. 3. Examine the drained fluid for evidence of engine coolant. 4. Examine the drained fluid for evidence of metal. Metal particles in the fluid, other than minute particles normally trapped in the oil filter, indicate internal transmission damage. When this occurs, inspect the inside of the oil pan for excessive metal particles. Refer to Oil Pan Replacement. 5. Metal contamination requires complete transmission disassembly. Notice: Flush the transmission cooling system and inspect for restrictions following a transmission failure. Failure to repair or replace restricted oil cooling system components may result in premature transmission failure. 6. Clean all internal and external hydraulic circuits, cooler, and all other areas where the particles could lodge. Refer to Transmission Fluid Cooler Flushing and Flow Test. Page 16740 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 1463 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 21703 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Page 13984 Use appropriate eye protection. 4. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Important Position the valve body as shown in the following illustrations for positive identification and location of individual parts. Page 19861 For vehicles repaired under warranty use, the table. Disclaimer Page 16710 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 15474 1. Connect the right park brake cable eye (2) to the park brake actuator lever. 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Notice: Refer to Fastener Notice. 3. Install the park brake cable clip bolt (2). Tighten the bolt to 22 N.m (16 lb ft). 4. Connect the park brake cable (1) to the rear axle housing cover clip. Page 7151 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Locations Intake Air Temperature Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 11232 Page 12513 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 19823 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Page 18485 Installation Procedure 1. Install the inlet heater hose. 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Important: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 23101 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 7904 Page 8085 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 12971 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 7857 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 3179 5. Remove the knock sensor bolt and sensor. Installation Procedure Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). Page 12669 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 206 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 19645 For vehicles repaired under warranty, use the table above. Disclaimer Page 24451 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Page 23883 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Page 954 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 23862 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 6743 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 2616 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 2114 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 19707 Page 17204 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 8530 Vehicle Zoning Strategy Truck Zoning Page 16193 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 13043 12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. Important: RPO M33 transmissions do not use a 1-2 accumulator spring inner (104). 13. Assemble the 1-2 accumulator assembly (54, 56, 57, 104). Ensure that the piston legs face the accumulator cover. 14. Install the 1-2 accumulator cover (57) and pin. 15. Install the 1-2 accumulator cover and the accumulator cover bolts. Tighten the bolts to 11 N.m (97 lb in). 16. Remove the J 25025-B from the transmission case. 17. Install the valve body. 18. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. Page 8946 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 5020 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 2053 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Input Speed Sensor (ISS) Harness Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Install drain pans under the vehicle as needed. Notice: Refer to Power Steering Hose Disconnected Notice. Important: Note the routing of the power steering gear inlet hose before removal. It MUST be routed correctly upon installation. 2. Remove the power steering gear inlet hose (2) from the power brake booster (1). 3. Remove the power steering gear inlet hose (2) from the power steering gear. 4. Remove the power steering gear inlet hose (2) from the vehicle. Installation Procedure Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Page 6170 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12937 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 6605 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 14746 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 24212 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 10907 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 616 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 10574 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 2493 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 20883 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Page 8948 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 24548 16. Return to the appropriate the Fuse Removal service procedure in this bulletin to continue this repair. Question and Answer Section Question and Answer Section Q1. Why are we compensating customers for a recall? A1. This is a special case where we are not confident a repair would work. This is why we are removing this feature from the vehicle. Compensating the current customer of record for this loss is an appropriate gesture. Q2. What is the original cost of the Heated Washer Fluid System? A2. The system was priced in several ways; as standard equipment, as a stand-alone option and as part of an option package. We analyzed these scenarios and determined that $100 is an appropriate estimate of the value of the feature. Q3. How much will each customer receive? A3. Customers will receive a $100 check from their servicing dealer within 30 days of recall completion. Q4. Why can't GM issue the checks? A4. Due to their age, our original sales records will not reflect any subsequent vehicle transactions or owner changes. Additionally, we don't have an in-house system that can handle this number of checks. So we are depending on our dealers to help execute this safety recall. Q5: When will customers be notified about having this feature disabled? A5: Customers should begin receiving letters in the mail in mid-June. However, they can go to their local dealer any time (even in advance of receiving a letter) to have the system disabled. Q6. Are all of the VINs involved in this recall identified in the GWM-IVH (GMVIS2) application? A6. Yes, all involved VINs have been updated for this recall. Q7. How do I identify the current customer of record? A7. For the purposes of this recall, the current customer of record is to be identified as the person or company whose name appears on the vehicle's state registration document or other legally recognized proof of vehicle ownership (unless specifically excluded). Prior to issuing the $100.00 check, please ensure the proof of ownership documentation has not expired and is otherwise valid. Q8. What should I do if proof of vehicle ownership is not available? A8. If proof of vehicle ownership documentation is not currently available or is otherwise invalid, the $100 check should not be issued. Q9. What if the customer objects to this policy? A9. If valid proof of ownership documentation is not available, the decision not to issue the $100 check is correct. If the customer still disagrees, please refer him/her to the GM Customer Assistance Center. Q10. If a check is not issued, how should the recall claim be submitted? A10. If a final determination is made not to issue a check, the $100 net item amount should not be claimed. Only the labor cost for the repair should be submitted. Q11. Can you provide examples of the various customer scenarios I can expect? A11. Certainly, listed below are examples with the preferred resolution. ^ Retail Customer - Vehicle Purchased Issue check to the customer at vehicle pickup if valid proof of vehicle ownership documentation is available. All checks must include the complete 17 character Vehicle Identification Number. ^ Retail Customer - Vehicle Leased Issue check to the customer at vehicle pickup (not GMAC or other financial institution) if valid proof of vehicle ownership documentation is available. Page 5421 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 23549 Page 15939 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 7605 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 4571 Step 8 - Step 13 Page 17634 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Page 11770 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 204 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 10460 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 24504 Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 14. After this procedure has been performed, issue a check to the customer or record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2006-2007 HUMMER H2 1. Open the hood and disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block in the engine compartment is located on the driver's side of the vehicle near the battery. Lift the cover for access to the fuse/relay block. Refer to Underhood Fuse Bock in the Owner's Manual for fuse information. 2. Locate the under-hood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer Mega fuse. 4. Remove the two nuts (1) for the Mega fuse (2). Refer to the picture. 5. Remove the 60 amp heated windshield washer Mega fuse. 6. Discard the 60 amp heated windshield washer Mega fuse. 7. Install the two nuts back into the two studs. 8. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 9 in this section of the bulletin. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. Page 16716 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 9153 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 23316 Page 17096 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 4081 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 1973 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 3961 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 15848 Page 22432 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 2107 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 21687 1 - Outside Rearview Mirror - Passenger 2 - Door Lock Switch - Passenger (AU3 -AN3/DL3) 3 Passenger Door Switch (PDS) (AN3/DL3) 4 - Door Latch Assembly - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) 6 - Speaker - Right Front 7 - Window Motor - Passenger (A31) 8 - Window Switch - Passenger (A31 -AN3/DL3) 9 - Heated Seat Switch Passenger (AN3) Driver Door (AU3 -AN3/DL3) Page 10278 Page 12157 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 2642 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 12195 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 2967 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 9774 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Navigation Radio - Volume/Tuner Knob Availability Navigation System: All Technical Service Bulletins Navigation Radio - Volume/Tuner Knob Availability INFORMATION Bulletin No.: 08-08-44-025A Date: September 11, 2008 Subject: Information On Navigation Radio Tuner And Volume Knobs Now Available For Service Replacements Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models 2008-2009 HUMMER H2 Models with Navigation Radio (RPOs UVB or U3U) Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin Number 08-08-44-025 (Section 08 - Body and Accessories). The purpose of this bulletin is to announce that the Navigation Radio tuner and volume knobs are now available for service replacements. Previously, if either of these knobs was worn or broken, the entire radio assembly had to be replaced. The same part number is to be used for either knob. They are identical. Parts Information Disclaimer Page 4691 31. Connect the control port injector module (1). 32. Connect the following electrical connectors: * The A/C compressor clutch (2), if equipped * The A/C pressure switch (1), if equipped A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 22995 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Procedures Parking Brake Cable: Procedures Parking Brake Cable Adjuster Disabling Parking Brake Cable Adjuster Disabling Before any components of the parking brake system are serviced, the following procedure must be followed. Two technicians are required to perform this procedure, one inside the vehicle and one outside the vehicle. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Hold the pedal in the FULL upward position. 3. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position. 4. Insert a thin tool (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3). 5. Slowly release the cable. 6. Remove the component that requires service. Parking Brake Cable Adjuster Enabling Parking Brake Cable Adjuster Enabling 1. Hold the park brake pedal in the FULL upward position. 2. Pull rearward on the front park brake cable until the tension is released from the tool (1) installed in the pedal assembly. 3. Remove the tool (1). 4. Slowly release the park brake cable until it returns to its original position. 5. Release the park brake pedal. Page 22539 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 7963 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 8075 Page 14341 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 6184 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 7867 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 7868 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 14450 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 24652 Page 12778 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 2804 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 917 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 22444 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 4882 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Disconnect the engine wiring harness electrical connector (4) from the crankshaft position (CKP) sensor. Page 10080 6. Disconnect the EVAP vent solenoid pipe quick connect fitting (3) from the EVAP canister. 7. Disengaging the retainer (1) securing the EVAP canister vent solenoid. 8. Slide the EVAP canister vent solenoid off the bracket towards the front of the vehicle. 9. Remove the EVAP canister vent solenoid from the vehicle. Installation Procedure 1. Position and install the EVAP canister vent solenoid to the vehicle. Page 12916 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. Tighten the bolts to 12 N.m (108 lb in). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. I/P Fuse Block Fuse: Locations I/P Fuse Block Fuse Block - I/P, Label Page 23129 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 6784 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6586 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 7348 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 18523 Low Pressure Sensor / Switch: Locations HVAC - Manual HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 2894 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 3554 Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: * Tearing * Piercing * Arcing * Corroded terminal If corrosion, or arcing are indicated on a spark plug wire boot a terminal, replace the wire and inspect the components connected to the wire. Page 5069 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 2399 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 9311 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 12123 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 23571 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 9117 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 12862 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 10902 Air Flow Meter/Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 3894 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 5290 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 7826 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 13396 Seals and Gaskets: By Symptom Technical Service Bulletin # 09-07-30-004C Date: 110113 A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. Page 11078 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 13901 Transmission Mount: Testing and Inspection 6L50/6L80/6L90 Transmission Mount Inspection Transmission Mount Inspection Notice: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the rubber. 2. Observe the transmission/transaxle mount while raising the transmission/transaxle. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: Important: Black paint on the rubber will crack with time, this does no constitute a failure. * The hard rubber surface is covered with heat check cracks. * The rubber is separated from the metal plate of the transmission/transaxle mount. * The rubber is split through the center of the transmission/transaxle mount. 3. If there is movement between the metal plate of the transmission/transaxle mount and its attaching points, lower the transmission/transaxle on the transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount to the frame or transmission/transaxle mount bracket. Page 24675 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 11415 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 14075 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Connect the internal wiring harness electrical connectors to the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) 23. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 24. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 18977 Disclaimer Page 16115 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 9142 Vehicle Zoning Strategy Truck Zoning Page 5413 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 421 Page 1275 Transmission Control Module (TCM) 80-Way Connector (Part 2) Page 20736 1. Install the door lower striker (2). 2. Install the spacer, if equipped. 3. Install the door lower striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. Notice: Refer to Fastener Notice. 5. Tighten the lower striker bolts. Tighten the door lower striker bolts to 24 N.m (18 lb ft). Page 5367 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 8309 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 16057 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Locations Central Control Module: Locations Entertainment/Communication Component Views Behind the I/P 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 +YE9) 6 - Digital Radio Receiver (U2K) Page 18605 Control Module HVAC: Diagrams HVAC Connector End Views Blower Motor Control Module X1 Blower Motor Control Module X2 Page 9194 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 9101 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 7360 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 3534 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Page 8917 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 3365 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 1779 Page 22339 Rear Seat Cushion Cover and Pad Replacement (Extended Cab with A68) Page 4636 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the drain plug and drain the engine oil in a suitable container. 3. Remove the oil filter. 4. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the oil filter gasket with clean engine oil. Notice: Refer to Fastener Notice. 2. Install the oil filter. Tighten the filter to 30 N.m (22 lb ft). Power Steering Fluid Cooler Replacement (Without Hydroboost) Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Replacement (Without Hydroboost) Power Steering Fluid Cooler Replacement (Without Hydroboost) Removal Procedure 1. Remove the radiator grille. 2. Remove as much power steering fluid as possible from the power steering fluid reservoir. 3. Place drain pans under the vehicle as needed. Notice: Refer to Power Steering Hose Disconnected Notice. 4. Disconnect the power steering gear outlet hose (2) from the power steering fluid cooler (4). 5. Disconnect the power steering fluid cooler hose (3) from the power steering pump (1). 6. Remove the power steering fluid cooler bolts (2) from the power steering fluid cooler (1). 7. Remove the power steering fluid cooler from the vehicle. Installation Procedure 1. Install the power steering fluid cooler to the vehicle. Page 17376 Page 11380 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 9630 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 22624 11 - Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) 12 - Seat Adjuster Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor Passenger (AN3) Page 16093 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 1277 Transmission Control Module (TCM), Engine Side Page 5823 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Binding In many cases, applying the proper lubrication can correct the following conditions: * Binding or sticking door lock cylinders * Difficulty in inserting and removing the keys For lubricating the above components, use lubricant GM P/N 12346241 or equivalent. Do not use penetrating lubricants such as GM P/N 1052949 or WD-40(R). Penetrating lubricants wash out the original lubrication. Penetrating lubricants eventually evaporate, leaving little or no lubricating material. However, when using penetrating lubricants in order to thaw or in order to loosen the lock cylinder components, refer to steps 2-4 in the procedure below for the proper methods of lubrication. Repair lock cylinders frozen in cold weather by using the following procedure: 1. While carefully avoiding damage to the painted surfaces, apply heat to the cylinder with a heat gun. 2. Using a paper clip or a similar item, hold the door shutter open. Force air into the cylinders using compressed air through a blow gun attachment. 3. While holding the shutter door open, inject small amounts of a recommended lubricant into the cylinder. 4. Work the key into the cylinder repeatedly. Wipe away any excess lubrication from the key. Page 22911 Page 232 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 15690 Page 11347 Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CMP sensor, install a NEW O-ring seal onto the sensor. 2. Install the CMP sensor to the wiring harness jumper. 3. Connect the CMP sensor wiring harness jumper to the CMP sensor. 4. Lubricate the O-ring seal with clean engine oil. 5. Install the CMP sensor and wiring harness jumper to the engine front cover. Notice: Refer to Fastener Notice. 6. Install the CMP sensor bolt. Tighten the bolt to 10 N.m (89 lb in). 7. Install the water pump. 8. Connect the engine wiring harness electrical connector (7) to the CMP sensor wiring harness jumper. Page 5994 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Service and Repair Carrier Bearings: Service and Repair Differential Side Bearings Replacement (All Except 9.75 Inch Axle) Tools Required * J 22912-B Split Plate Bearing Puller * J 8092 Universal Driver Handle - 3/4 in - 10 * J 21784 Side Bearing Installer * J 22888-D Side Bearing Remover Kit * J 29710 Differential Side Bearing Installer * J 36597 Side Bearing Puller Pilot - 9.25 Axle * J 44420 Differential Bearing and Hub Seal Installer Removal Procedure 1. Remove the differential assembly. 2. Remove the differential side bearings by doing the following: 1. For the 8.6 inch, 9.5 inch, 11.5 inch axles, install the differential assembly into a vise. 2. For the 10.5 inch axle, place a block of wood on each side of the differential assembly. Install the differential assembly into a vise. 3. Install the J 22888-20A (2) and the J 8107-4, 8.6 inch axle, or the J 36597, 9.5 inch or 10.5 inch axle, or the J 8107-5, 11.5 inch (1) axle, over the differential case side bearing bore. 4. Remove the differential side bearings using the J 22888-20A. Installation Procedure 1. For the 8.6 inch, the 9.5 inch, and the 10.5 inch axles, install the differential side bearings by doing the following: 1. In order to protect the differential case, install the J 8107-4, 8.6 inch axle, or the J 36597, 9.5 inch or 10.5 inch axles, in the case on the side opposite the bearing installation. 2. Install the J 21784, 8.6 inch axle, or the J 29710, 9.5 inch or 10.5 inch axles (2), and the J 8092 (1) onto the differential case bearing as shown. 3. Drive the bearing onto the case using the J 21784 or the J 29710 and the J 8092. Page 6449 Knock Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 23151 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 21971 Sun Shade: Service and Repair Sunroof Sunshade Replacement (Crew Cab) Sunroof Sunshade Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. 2. Remove the screws (1) that retain the water trough to the sunroof assembly. 3. Remove the water trough from the sunroof assembly from the top of the vehicle. Important: The sunshade must be removed from the top of the vehicle. 4. Slide the sunshade forward. 5. Flex the center of the sunshade (2) upward while simultaneously sliding the panel sideways to release the retaining tabs (3) from the track slot (1). 6. Remove the sunshade from the top of the vehicle. Installation Procedure 1. Position the sunshade to the vehicle from the top of the vehicle. 2. Install the retaining tabs on the far side of the sunshade, starting with the center tab first in the track slot of the sunroof. 3. Flex the center of the sunshade (2) upwards while simultaneously inserting the retaining tabs (3) into the track slot (1). 4. Ensure that the sunshade tabs are fully seated in the track slots, and the sunshade slides smoothly. Page 12072 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 3861 Fuse: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 447 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11311 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Instruments - Hard to See/Poor Backlighting Instrument Panel Control Module: All Technical Service Bulletins Instruments - Hard to See/Poor Backlighting Bulletin No.: 07-08-49-029A Date: January 25, 2008 TECHNICAL Subject: Instrument Panel (IP) Gauges/Gages Difficult to Read or See Poor Backlighting (Replace IP and Program) Models: 2007 Chevrolet Avalanche Silverado Suburban Tahoe 2007 GMC Sierra Sierra Denali Yukon Yukon Denali Yukon XL Yukon Denali XL Supercede: This bulletin is being revised to reflect the latest Utility software part number. Please discard Corporate Bulletin Number 07-08-49-029 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) gauges are difficult to read due to poor backlighting. This condition does not affect the IP cluster operation. Correction DO NOT program the service software into existing 2007 clusters. The service software is designed to work only with the 2008 cluster hardware, which includes a new microprocessor. For IP clusters replaced/programmed due to a customer concern of poor backlighting, warranty claims must be submitted using the labor operation listed in this bulletin. Refer to the Warranty Section for more information. Program the replacement IPC using TIS2WEB Pass-Thru Programming. Select "I/PC" from the Supported Controllers table in TIS2WEB to complete the programming. DO NOT select I/PC Set-up. Mileage and/or Engine Hours must be set by the ESC's prior to installing the IP in the vehicle. DENALI CUSTOMER'S ONLY - Please advise the customer that 2008 Denali clusters are not available. In order to correct this condition, a 2008 Yukon or Sierra cluster will have to be installed in the vehicle. The customer must advise the dealer whether they wish to keep the current 2007 Denali cluster or replace it with a 2008 Yukon or Sierra cluster (which will correct the condition). Programming a 2007 cluster with the 2008 service software can drain the battery and potentially cause a "no start" condition. If the customer is dissatisfied with the IP cluster visibility the current (2007) cluster should be replaced with the 2008 hardware/software. Refer to the charts listed in the Parts Information section of this bulletin to determine the new IP cluster and software part numbers. Page 5167 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 24297 Tighten bolt to 11 N.m (97 lb in). 6. Install the rear sliding window lower garnish molding. 7. Inspect the rear sliding window for proper operation. Page 23081 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 23156 Page 8611 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Service and Repair Stabilizer Link: Service and Repair Stabilizer Shaft Link Replacement (1500) Page 14130 Installation Procedure 1. Align the tabs on the new wiring harness (10) U-channel with the solenoid retainer slots for SS3 (3) and SS2 (2) on the control valve assembly. Install the solenoid retainers (12) for the SS3 (3) and SS2 (2) solenoids. Important: The internal wiring harness connectors should be in the correct position for installation because of their pre-assembled position in the U-channel. 2. Attach the internal wiring harness (10) connectors to the solenoids, the IMS, and the TFP switch. * Connector (8) goes to SS1 (5) * Connector (9) goes to the TFP switch (7) * Connector (11) goes to the MAIN MOD solenoid (19) * Connector (13) goes to the IMS * Connector (14) goes to the TCC PCS (1) * Connector (15) goes to SS2 (2) * Connector (16) goes to SS3 (3) * Connector (17) goes to PCS1 (4) * Connector (18) goes to PCS2 (6) Page 11551 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 12034 Tighten the bolt to 11 N.m (97 lb in). 6. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 9. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Locations Air Bag Deactivation Switch: Locations SIR Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 11069 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 6802 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 20056 Radio Rear Side Door Speaker Replacement (Extended Cab) Radio Rear Side Door Speaker Replacement (Extended Cab) Page 9171 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components Refer to SIR Identification Views. There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. Page 11736 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 16468 X220 Inline Harness Connector End Views X220 Brake Clutch Harness to Chassis Harness (JL1) X224 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0/5X7) Page 16090 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 24694 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 9854 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 7283 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 11258 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 16332 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 6159 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 6201 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 12683 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 11938 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 24238 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 1456 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 944 Vehicle Zoning Strategy Truck Zoning Page 2976 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 18405 Disclaimer Page 7843 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 8973 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 18444 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P C4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 202 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 5738 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 10948 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 20905 Owner Letter Owner Letter July 2010 Dear GM Customer: As the owner of a 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, or Yukon XL vehicle, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles may have a peeling condition on the top surface of the front or rear chrome interior door handle(s) that could create a rough edge. A chrome plating irregularity combined with direct sunlight exposure may cause the plating to separate from the top surface of the handle. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners of 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles with additional protection for the front and rear chrome interior door handles. If this condition occurs on your 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, or Yukon XL within 10 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by July 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. Scott Lawson Director, Customer and Relationship Services Enclosure 09239 Page 14177 11. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 12. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. Page 22538 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 7946 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 16167 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 3085 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 6052 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 17129 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 8880 Engine Control Module: Locations Engine Controls Component Views Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 12828 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 23099 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Body - Chrome Outside Door Handle Loose/Cracked Front Door Exterior Handle: All Technical Service Bulletins Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Page 23431 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 11919 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 14588 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Fastener Tightening Specifications Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 14903 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 8133 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 23931 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 8542 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 22688 Tighten the bolts to 22 N.m (16 lb ft). Install the center front seat. Refer to Center Seat Replacement in SI. Install the front seats. Refer to Front Seat Replacement in SI. Install the front seat belts to the seats. Refer to Seat Belt Retractor Pretensioner Replacement in SI. Install the front hinge pillar trim panels. Refer to Body Hinge Pillar Trim Panel Replacement in SI. Install the front door sill plates. Refer to Front Door Sill Plate Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2819 Page 5260 Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement (Non-HP2) Page 15032 Fluid Pressure Sensor/Switch: Service and Repair Allison - Automatic Transmission Pressure Switch Manifold Replacement Removal Procedure Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Caution: Refer to Battery Disconnect Caution. 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Page 5562 Disclaimer Page 8157 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 4031 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 22449 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 1001 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 9760 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 17740 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Page 16973 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 9943 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: * The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. * Apply the park brake. * The engine must start in the park (P) or neutral (N) positions only. * Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 16960 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 11840 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 19125 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Page 20563 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Brace Replacement Front Bumper Impact Bar Brace Replacement Page 2235 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 16462 X211 Inline Harness Connector End Views X211 Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) to Console Harness (Y91/UQA/D07) Front Bumper Fascia Trim Cap Replacement (GMC) Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Trim Cap Replacement (GMC) Front Bumper Fascia Trim Cap Replacement (GMC) Page 14571 21. Remove the spacer plate support bolts (77). 22. Remove the spacer plate support (53). 23. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). Notice: Refer to Fastener Notice. 2. Install the spacer plate support (53) and bolts (77). Tighten the bolts to 10 N.m (89 lb in). Procedures Steering Angle Sensor: Procedures Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 21373 Carpet: Service and Repair Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Page 2058 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 7125 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 1964 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 13468 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement. Page 10274 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 6666 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 6291 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 12143 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 6155 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 5101 Page 1050 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Notice: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Important: It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. 3. Disengage the engine wiring harness upper electrical connector retainer (2) and remove the connector (1) from the ECM. 4. Disengage the engine wiring harness lower electrical connector retainer (3) and remove the connector (4) from the ECM. Page 10220 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 7334 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 23636 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 16693 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 11226 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Lighting - Turn Signals Have Increased Flash Rate Body Control Module: All Technical Service Bulletins Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9615 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 281 Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagrams can be found via their numbers at Vehicle Locations. See: Locations Page 17030 Page 14773 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 13631 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (367A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Page 10068 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 21508 Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement Body Hinge Pillar Trim Panel Replacement Body Lock Pillar Trim Replacement (Crew Cab) Body Lock Pillar Trim Replacement (Crew Cab) Page 6034 Air Flow Meter/Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 14456 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 280 Heated Seat References Body - Outside Door Handle Pulls Out of Base Rear Door Exterior Handle: Customer Interest Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information Page 11455 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 17234 Disclaimer Page 18269 2. Install the blower motor to the heater/ventilation module. Turn the blower assembly clockwise until the retaining tab locks into place. 3. Install the blower motor insulating cover. 4. Connect the electrical connector to the blower motor. Notice: Refer to Fastener Notice. 5. Install the blower motor insulating cover screws. Tighten the screws to 1.6 N.m (14 lb in). 6. If equipped, install the sound insulator panel. Page 3672 7. Cycle the ignition until Drive or Reverse range is attained. Important: Fluid remains in the external circuits and transmission cavities after draining the transmission. 8. Check the transmission fluid level. Page 5907 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Valve Rocker Arm Cover Replacement - Left Side Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Left Side Valve Rocker Arm Cover Replacement - Left Side Removal Procedure 1. Remove the engine wiring harness bracket nuts. 2. Remove the engine wiring harness bracket. 3. Remove the engine wiring harness clip bolt (4). 4. Disconnect the engine coolant temperature (ECT) sensor electrical connector (5). 5. Reposition the engine wiring harness and bracket. 6. Disconnect the power brake booster vacuum hose from the vacuum fitting. Page 10243 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 22248 4. Using a drill with a 5/16 drill bit, or equivalent, pierce holes through the trim and plastic J-retainer at the marked locations on each end of the seat cushion trim. 5. Pushing only approximately 1/4 of the way through, insert a push pin retainer (1) into the drilled holes on each side of the J-retainer. 6. Reposition the seat cushion and cover, and roll the J-retainer and trim to install position. 7. Attach the J-retainer to the seat cushion pan on one side by positioning the push pin retainer (1) to the rear side of the slot on cushion pan, and pushing forward to fully seat the push pin in the slot. 8. Repeat step 7 on the opposite end of J-retainer. 9. The seat cushion cover will now have better retention to the seat frame, and exhibit an improved fit across the forward edge of the seat. Parts Information Purchase the tape locally. Page 3005 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11329 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 10445 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 11891 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 17967 * When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system, brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. * When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within 50 mm (2 in) of any radius. * Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed. * When major components are removed from the vehicle when supported on a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and secure the vehicle frame to the hoist pads nearest the component to be removed. Vehicle Jacking * Park the vehicle on a clean, hard, level surface before jacking the vehicle. * Any time you lift the vehicle on one end, chock the wheels at the opposite end. * Use jack stands in order to provide support. * When supporting the vehicle using jack stands, place the jack stands under the side rails or the axle. * When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar or mounting hardware. Page 21122 Page 17656 Important: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 3. Mount the tire to the rim. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 6752 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 23330 Page 10794 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10098 4. Inspect for fuel leaks. Page 2029 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 1864 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 111 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Page 208 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 21983 1. Position the sunroof motor/actuator (3) to the sunroof module. 2. Push the sunroof motor/actuator straight upward to engage the drive gear between the cables housed within the sunroof cable drive tubes. Notice: Refer to Fastener Notice. 3. Install the sunroof motor/actuator screws (2) to the sunroof actuator. Tighten the screws to 4 N.m (35 lb in). 4. Connect the electrical connector (1) to the sunroof motor/actuator. 5. Install the headliner. 6. Initialize/teach the sunroof motor/actuator. Refer to Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor). 7. Inspect the sunroof for proper operation. 8. Refer to Control Module References for programming and setup information. See: Testing and Inspection/Programming and Relearning Page 20622 occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 08-08-64-007 Date: 080513 Body - Outside Door Handle(s) Squeak When Operated TECHNICAL Bulletin No.: 08-08-64-007 Date: May 13, 2008 Page 24671 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 22496 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 1110 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 17432 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 5034 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 17571 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Audio System - Static/Ignition Noise on AM Band Ignition Cable: Customer Interest Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Page 5716 Body Control Module (BCM) X6 Page 4615 Engine Oil: Fluid Type Specifications ENGINE OIL TYPE LOOK FOR TWO THINGS: 1.Your vehicle's engine requires oil meeting GM Standard GM6094M. 2.SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). You should look for this information on the oil container, and use only those oils that are identified as meeting GM Standard GM6094M and have the starburst symbol on the front of the oil container. NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES Do not add anything to your oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all you will need for good performance and engine protection. Page 11436 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12092 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 17396 X800 Right Rear Door Harness to Body Harness (Extended Cab) Page 2255 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 13986 Page 1598 Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 3. Remove the fuel pump/oil pressure sensor fitting, if necessary. Installation Procedure 1. If installing the old fitting, apply sealant to the threads of the fitting. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 2. Install the fitting until snug, if necessary. Notice: Refer to Fastener Notice. 3. Tighten the fuel pump/oil pressure sensor fitting. 1. Tighten the fitting to 15 N.m (11 lb ft). 2. Increase torque until the centerline of the fitting (1) is 50 degrees from the centerline of the crankshaft (2). Page 12914 Shift Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. Important: * When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall Page 11102 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 18295 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Page 5362 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 1956 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 14853 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6885 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 5309 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 4901 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 3332 17. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 18. Remove the 7 valve body checkballs. Important: Some models do not have an outer spring. Note spring usage during removal. 19. Remove the accumulator cover bolts (58, 59). 20. Remove the 1-2 accumulator cover and pin assembly (57). Page 16932 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 16241 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 16486 Inline Harness Connector End Views X321 Body Harness to Headliner Harness (A48) X322 Inline Harness Connector End Views X322 Body Harness to UPA Jumper Harness (UD7) Page 12320 Transmission Control Module (TCM) 80-Way Connector (Part 2) Page 12349 Fluid Pressure Sensor/Switch: Service and Repair Allison - Automatic Transmission Pressure Switch Manifold Replacement Removal Procedure Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Caution: Refer to Battery Disconnect Caution. 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Page 10222 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 7228 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 12684 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 16268 Page 24214 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 6874 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 11677 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 7589 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 24192 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 15876 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 1651 Dimmer Switch: Diagrams Lighting Systems Connector End Views Headlamp and Panel Dimmer Switch Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 13677 Shift Cable: Adjustments 6L50/6L80/6L90 - Automatic Transmission Range Selector Lever Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Page 8275 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 20766 3. Install the weatherstrip (1) to the pinch-weld flange (2). Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Refer to Front Side Door Sill Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Plate Replacement (Extended Cab) or Rear Side Door Sill Plate Replacement (Extended Cab) Rear Side Door Sill Plate Replacement (Crew Cab) . Page 18206 Mode Actuator Replacement Mode Actuator Replacement Page 11857 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 9037 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 11382 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 7772 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Page 24545 dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Windshield Washer Solvent Heater Removal WINDSHIELD WASHER SOLVENT HEATER REMOVAL 1. Disconnect the windshield wiper solvent inlet and outlet hoses (1) from the windshield washer solvent heater assembly and from the two plastic inlet and outlet windshield wiper solvent hoses. Note Do NOT remove the connector retention clips from the connectors. Do NOT remove the assembly bracket from the engine compartment. 2. Disconnect the two electrical connectors at the windshield washer solvent heater assembly. 3. Remove the windshield washer solvent heater assembly from the assembly bracket using a small flat blade screwdriver. 4. Place the windshield washer solvent heater assembly on a work bench. 5. Cut the two-wire connector from the windshield washer solvent heater assembly. Vary the length of the red and black wires on the connector. Refer to illustration. Page 12322 Transmission Control Module (TCM), Engine Side Page 18595 Disclaimer Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 23909 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 18133 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 13864 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Page 11135 Throttle Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Locations Turn Signal Switch: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 6562 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. Notice: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 2. Remove the MAP sensor bolt (1). 3. Using a slight rocking motion while pulling straight up, remove the MAP sensor (2) from the upper intake manifold. 4. Inspect the MAP sensor seal for damage, replace the seal if necessary. Installation Procedure Page 17120 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch Page 22490 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 11992 Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (2) up and over the knock sensor. Locations Intake Air Temperature Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 14062 306 - Control Valve Body Ball Check Valve 307 - Control Valve Lower Body Assembly 308 A/Trans Manual Shift Shaft Position Switch Assembly 309 - Bolt, M5 x 45 mm 310 - Bolt, M5 x 55 mm 311 - Filter Plate Assembly 312 - Bolt, M5 x 53 mm 314 - Control Solenoid (w/ Body and TCM) Valve Assembly 315 - A/Trans Manual Shaft Position Switch Wiring Harness Clip 316 - A/Trans Input and Output Speed Sensor Wiring Harness Clip Upper Control Valve Body Assembly Disassembled Views (6L90) Upper Control Valve Body Assembly 313 - Control Valve Body Locator Pin 321 - Control Valve Upper Body 322 - Control Valve Body Locator Pin 323 - Retainer 324 - Actuator Feed Limit Valve Spring 325 - Actuator Feed Limit Valve 326 - Clutch Regulator Valve Spring 327 - CBR1/4-5-6 Clutch Regulator Valve 328 - Clutch Regulator Valve Bore Plug 329 - Clutch Boost Valve 330 - Clutch Boost Valve Spring 334 - 2-6 Clutch Regulator Valve 335 - 2-6 Clutch Regulator Valve Gain Valve 336 - 3-5 Reverse Clutch Regulator Valve 337 - 1-2-3-4 Clutch Regulator Valve 338 - Shuttle Valve Page 498 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 16182 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 15135 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (JH6/JH7) Electronic Brake Control Module (JH6/JH7) Page 22888 Disclaimer Page 16067 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 4909 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 1929 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 3103 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 12077 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 15869 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 7970 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 24704 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 6328 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 13074 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 12237 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 4849 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Page 11185 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 6160 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 728 Parts Information Warranty Information For IP clusters replaced/programmed due to customer satisfaction concerns of poor backlighting, the warranty claim MUST be submitted using the labor operation listed in this bulletin. Disclaimer Page 8465 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6338 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 16087 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 853 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 15841 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Auxilary Power Outlet - Center Seat (AZ3) 1 - Auxilary Power Outlet - Center Seat (AZ3) Console Components Page 9706 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 15900 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 10866 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 22262 Disclaimer Page 23158 Cigarette Lighter: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure Page 7386 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 12045 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. 6. Enable the SIR system. Page 12040 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. 6. Enable the SIR system. Page 9867 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Service and Repair Coolant Line/Hose: Service and Repair Water Outlet Tube Replacement (LU3) Removal Procedure 1. Remove the air cleaner outlet resonator duct. 2. Remove the radiator inlet hose. 3. Remove the turbocharger coolant bypass valve. 4. Remove the water outlet bolts. 5. Remove the water outlet. 6. Remove and discard the gasket. Installation Procedure 1. Install a NEW gasket to the water outlet. Page 9322 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 22323 Page 15920 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 5910 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 5974 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 11762 Vehicle Zoning Strategy Truck Zoning Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 3118 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 22451 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 24708 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8443 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 8890 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 22741 Tailgate Shock / Support: Service and Repair Pickup Box Endgate Cable Bolt Replacement Pickup Box Endgate Cable Bolt Replacement Page 1079 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 18439 7. Assemble the A/C components. Refer to the appropriate repair procedure. * For compression style fittings use a back up wrench on the fitting (2) and tighten the fitting nut (1) to specification. * For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification. Page 11354 Evaporative Emission Canister Vent Solenoid Valve Replacement (Regular Cab w/26 Gal Tank) Canister Vent Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Valve Replacement (Regular Cab w/26 Gal Tank) Evaporative Emission Canister Vent Solenoid Valve Replacement (Regular Cab w/26 Gal Tank) Removal Procedure Important: Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove EVAP canister vent solenoid clip (1) from the chassis EVAP line. 3. Remove the EVAP canister vent solenoid pipe from the clip (2) on the chassis EVAP line. 4. Remove the EVAP canister vent solenoid pipe from the clips (3) on the brake pipes. 5. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid. Page 4035 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 4097 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 2916 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Lighting - Brake Lamps Turn Off After Stop/Pedal Applied Brake Light Switch: All Technical Service Bulletins Lighting - Brake Lamps Turn Off After Stop/Pedal Applied TECHNICAL Bulletin No.: 08-08-42-003A Date: August 14, 2009 Subject: Stop Lamps Intermittently Turn Off After Coming to a Complete Stop While Still Having Pressure on Brake Pedal (Replace Stop Lamp Switch) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to provide a new part number. Please discard Corporate Bulletin Number 08-08-42-003 (Section 08 - Body & Accessories). Condition Some customers may comment on the stop lamps turning off prior to the brake pedal reaching the fully released position. Some customers may also comment on the stop lamps turning off while having light pressure on the brake pedal. Some customers with Integrated Trailer Brake Control (ITBC) may comment that the electronic trailer brakes disengage after the vehicle has come to a complete stop. This disengaging of the trailer brakes coincides with the stop lamps turning off. Cause This condition may be caused by not enough pressure being applied to the stop lamp switch to keep the brake lights on. Correction Technicians are to replace the stop lamp switch. The new stop lamp switch has a reduced internal spring apply force, which will allow the lamps to stay on with less applied brake force. 1. Refer to SI for Stop Lamp Switch replacement procedures. 2. Use the new Stop Lamp Switch, P/N 25981009. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9897 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 5440 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 5009 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 7091 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 8250 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 11206 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Wipers/Washers - Washer Fluid Leak on The Driver's Side Windshield Washer Pump: All Technical Service Bulletins Wipers/Washers - Washer Fluid Leak on The Driver's Side INFORMATION Bulletin No.: 08-08-43-006 Date: April 08, 2008 Subject: Information on Windshield Washer Solvent Leaking Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali If a customer comments that there is windshield washer solvent leaking from the front drivers side of the vehicle this condition may be caused by a cut or not properly seated washer pump grommet. Before replacing the washer pump inspect the condition of the grommet around the inlet of the washer pump. First make certain that the pump/grommet is fully seated in the washer solvent container. If a leak still exists then remove the pump from the container using care not to tear or cut the grommet during removal and inspect the grommet to make sure it's free of cuts or tears. Install the pump and grommet back into the container making sure to use washer solvent to lubricate the grommet. Inspect for leaks again. If the washer solvent still leaks be sure to inspect the outlet hose for a proper connection. Make every effort to inspect all components before ordering a new part. DO NOT replace the washer pump unless you see that the pump is cracked or broken externally. If the grommet is torn or cut replace only the grommet. Disclaimer Page 1721 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 17855 Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (2WD 2500 HD, 3500) Drivetrain and Front Suspension Frame Front Crossmember Replacement (2WD 2500 HD, 3500) Page 7405 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 4926 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21377 Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 12378554 (Canadian P/N 88901678), may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 2473 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 2865 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 19598 Garage Door Opener Transmitter: Testing and Inspection Garage Door Opener Programming Universal (Three LEDs) Garage Door Opener Programming - Universal (Three LEDs) Important: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Be sure that people and objects are clear of the garage door you are programming. Programming the GDO for Rolling Code Receivers This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Press the two outside buttons on the GDO for one to two seconds and immediately release them. 2. Locate the train button on the garage door opener receiver. Follow instructions for the garage door opener in order to determine when the unit is in train mode. 3. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 5 to 20 seconds. The LED above the button will flash slowly. When the garage door moves, release the button. The LED will then flash rapidly until programming is complete. 4. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types of garage door openers. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the garage door opener. Call 1-866-572-2728 in order to address compatibility concerns. Programming the GDO for Fixed Code Receivers This procedure is for training the customer's fixed code garage door openers to their GDO transmitter. To determine if the customer has a fixed code garage door opener, remove the battery cover on the manufacturer's supplied transmitter. If a row of dip switches is present, the garage door opener is then a fixed code version. The transmitter should have anywhere from 8 to 12 switches. The garage door opener receiver may also have a set of dip switches. If the number of switches on the receiver and on the transmitter do not match, use the receiver switches to program the GDO. Each dip switch may have either two or three positions. The two position switch can either be on or off. The three position switch can either be on, neutral, or off. 1. Write down the positions of the dip switches. The positions of the switches will be entered from left to right into the GDO using the three buttons. 2. Press all three buttons on the GDO for about three seconds and immediately release them. The LEDs should flash slowly, indicating that the GDO is in programming mode. 3. Enter the positions of the dip switches one at a time. If a position of a dip switch is on, press the left button on the GDO. If the position is neutral, press the middle button of the GDO. If the position is off, press the right button of the GDO. Enter all of the positions of the dip switches. The procedure must be completed in two and one half minutes. 4. Press all three buttons on the GDO until all the LEDs turn on. 5. Press the button that you want trained to control the garage door. The LED above the button will flash slowly. You will have to hold the button from 5 to 55 seconds. When the garage door moves, release the button. The LED will then flash rapidly until programming is complete. 6. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types of garage door openers. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the garage door opener. Call 1-866-572-2728 in order to address compatibility concerns. Erasing Channels To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Page 5874 Engine Control Module X1 (Pin 25 To 73) Engine Control Module X2 Page 4922 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 8005 Page 7276 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 8387 Page 2523 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 669 Disclaimer Page 11543 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 5052 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 9837 Vehicle Zoning Strategy Truck Zoning Page 17591 4. Set the top edge of the level on the reference surface of the steering knuckle (C) and extend the level directly under the rear end of the front attachment bolt of the lower control arm (A). 5. While keeping the level in contact with the knuckle reference surface, adjust the level up/down until the bubble indicates it is horizontally level. 6. Extend a tape measure straight down from the center of the attachment bolt. The point where the tape measure and the level intersect is your first measurement. 7. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the front end of the rear attachment bolt of the lower control arm (B). 8. Extend a tape measure straight down from the center of he attachment bolt. The point where the tape measure and the level intersect is your second measurement. 9. Push the front bumper of the vehicle down about 38 mm (1.5 in) 10. Gently remove your hands and let the vehicle settle. 11. Repeat this operation 2 more times for a total of 3 times. 12. Re-measure the Z height. 13. The true Z height is the average of the measurements taken. Refer to Trim Height Specifications. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Z Height Adjustment 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion arm as needed. One revolution of the bolt (1) into the nut increases the Z height by approximately 6 mm (0.2 in). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. 3. If these measurements are still out of specifications after adjustment or are not equipped with torsion bars, inspect for the following: * Sagging front suspension-Refer to Torsion Bar and Support Assembly Replacement (Bushing Style). * Collision damage Page 6916 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 14896 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13712 Disclaimer Page 21630 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 20621 Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-023 Date: 090603 Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can Page 6699 Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (3). Tighten the sensor to 42 N.m (31 lb ft). 3. Install the HO2S pigtail electrical connector clip to the engine wiring harness clip (3). Page 12066 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 22472 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Instrument Panel Compartment Door Assembly Replacement (with RPO SLT) Glove Compartment: Service and Repair Instrument Panel Compartment Door Assembly Replacement (with RPO SLT) Instrument Panel Compartment Door Assembly Replacement (with RPO SLT) Page 11451 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 1205 Page 10582 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 9792 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 24739 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 9859 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 4004 Fuse Block: Locations HVAC - Manual HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 16196 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 10105 4. Inspect for fuel leaks. Page 11292 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 5860 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 13017 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 4099 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 6955 Page 19916 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Page 13358 Instruments - Hard to See/Poor Backlighting Instrument Panel Control Module: All Technical Service Bulletins Instruments - Hard to See/Poor Backlighting Bulletin No.: 07-08-49-029A Date: January 25, 2008 TECHNICAL Subject: Instrument Panel (IP) Gauges/Gages Difficult to Read or See Poor Backlighting (Replace IP and Program) Models: 2007 Chevrolet Avalanche Silverado Suburban Tahoe 2007 GMC Sierra Sierra Denali Yukon Yukon Denali Yukon XL Yukon Denali XL Supercede: This bulletin is being revised to reflect the latest Utility software part number. Please discard Corporate Bulletin Number 07-08-49-029 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) gauges are difficult to read due to poor backlighting. This condition does not affect the IP cluster operation. Correction DO NOT program the service software into existing 2007 clusters. The service software is designed to work only with the 2008 cluster hardware, which includes a new microprocessor. For IP clusters replaced/programmed due to a customer concern of poor backlighting, warranty claims must be submitted using the labor operation listed in this bulletin. Refer to the Warranty Section for more information. Program the replacement IPC using TIS2WEB Pass-Thru Programming. Select "I/PC" from the Supported Controllers table in TIS2WEB to complete the programming. DO NOT select I/PC Set-up. Mileage and/or Engine Hours must be set by the ESC's prior to installing the IP in the vehicle. DENALI CUSTOMER'S ONLY - Please advise the customer that 2008 Denali clusters are not available. In order to correct this condition, a 2008 Yukon or Sierra cluster will have to be installed in the vehicle. The customer must advise the dealer whether they wish to keep the current 2007 Denali cluster or replace it with a 2008 Yukon or Sierra cluster (which will correct the condition). Programming a 2007 cluster with the 2008 service software can drain the battery and potentially cause a "no start" condition. If the customer is dissatisfied with the IP cluster visibility the current (2007) cluster should be replaced with the 2008 hardware/software. Refer to the charts listed in the Parts Information section of this bulletin to determine the new IP cluster and software part numbers. Page 19808 Page 16984 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 15787 Alternator: Service and Repair Generator Replacement Generator Replacement (4.3L) Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the negative battery cable. 2. Remove the air cleaner outlet resonator. 3. Remove the drive belt. 4. Remove the engine wiring harness clip (1) from the air conditioning (A/C) compressor/condenser hose bracket. 5. Remove the A/C compressor and condenser hose bracket bolt (2). Page 11765 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Pressure Manual Valve Position Switch Logic Transmission Fluid Pressure Manual Valve Position Switch Logic Page 19910 Page 2461 Throttle Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 11912 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 21653 Disclaimer Page 22806 Figure 4 - Top View - Rear Structure Figure 5 - GM Cargo Management Points Caution Overloading the vehicle may cause damage. Do not overload the vehicle. When you carry removable items, you may need to put a limit on how many people you carry inside your vehicle. Be sure to weigh your vehicle before you buy and install the new equipment. Remember not to exceed the Gross Axle Weight Rating (GAWR) of the front or rear axle. If the vehicle is damaged due to overloading, repairs would not be covered by the vehicle warranty. The load bearing structural information is also included in the Body Builder's manual at www.gmupfitter.com. Disclaimer Page 11482 Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. ...............................................1,200-1,500 ohms per ft Driver Seat and Passenger Seat Back Cushion Heater Replacement Seat Heater: Service and Repair Driver Seat and Passenger Seat Back Cushion Heater Replacement Driver Seat and Passenger Seat Back Cushion Heater Replacement Page 13594 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 10743 Fuel System Control Module (LMG/LY6/LC9) Connector Part Information - OEM: 13570966 - Service: 89047377 - Description: 47-Way F 0.64 6.3 Series, Sealed (BK) Terminal Part Information - Pins: 1,16, 32, 47 - Terminal/Tray: 15476168/5 - Core/Insulation Crimp: F/3 - Release Tool/Test Probe: 15315247/J-35616-42 (RD) - Pins: 5-7, 10, 13, 15, 17, 21, 22, 36, 44 - Terminal/Tray: 7116-3703-02/14 - Core/Insulation Crimp: 9/9 - Release Tool/Test Probe: J-38125-215/J-35616-64B (L-BU) Entertainment System - Rear DVD Screen Inoperative/Blank DVD Player: All Technical Service Bulletins Entertainment System - Rear DVD Screen Inoperative/Blank TECHNICAL Bulletin No.: 06-08-44-032B Date: April 10, 2008 Subject: Rear (2nd and *3rd Row (*where applicable)) DVD Screen Blank/Inoperative, Speaker Pop Noise, Battery Draw, OnStar(R) Audio Inoperative, Nav Screen Flashing, Radio Display Flashing (Inspect and Repair Wiring Harness if Necessary) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT* 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe* 2007-2008 Chevrolet Equinox 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL* 2007-2008 Pontiac Torrent with Rear Seat Entertainment System (RPOs U42, UUC) Supercede: This bulletin is being revised to add RPO UUC. Please discard Corporate Bulletin Number 06-08-44-032A (Section 08 - Body and Accessories). Condition Some customers may comment on any one of the following concerns: ^ Rear DVD Screen Inoperative. ^ Pop Noise in all speakers when cranking the engine. ^ Battery Draw or Battery goes dead. ^ OnStar(R) Inoperative. ^ No Sound from speakers. ^ No OnStar(R) Audio. ^ Navigation screen "Flashing on and off". ^ Radio display "Flashing on and off". Cause This condition may be due to an open or shorted wiring harness near the rear DVD display screen under the headliner. Correction To properly inspect for this condition perform the following steps: 1. Lower the rear DVD screen. 2. Remove the four retaining screws that hold the DVD to the headliner. In order to remove the screen assembly from the overhead bezel a firm tug should be applied to unseat the Z-axis clip. Page 10905 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 22275 Disclaimer Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood, Label Diagrams Hazard Warning Switch: Diagrams Power and Grounding Connector End Views Roof Beacon Relay (TRW) Page 11155 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 22452 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Diagrams Pedal Positioning Switch: Diagrams Adjustable Pedal Connector End Views I/P Multifunction Switch Assembly Page 4376 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Page 3143 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 10560 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Interior - Lint Accumulation On Ebony Colored Seats Seat Cover: All Technical Service Bulletins Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 4288 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 4590 5. Remove the engine mount bolts. 6. Remove the engine mount. 7. If necessary, remove the engine mount side bracket bolts and bracket. 8. Remove the engine mount bracket bolts. 9. Remove the engine mount bracket. Installation Procedure 1. Install the engine mount bracket. 2. Perform the following procedure prior to installing the engine mount bracket bolts. 1. Remove all traces of the original adhesive patch. Page 2885 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1936 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 6296 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 7321 Page 2257 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 9066 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 11458 Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Page 23521 Brake Light Switch: Locations Lighting Systems Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 5708 Body Control Module: Locations Data Communication Component Views Behind the I/P 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) (Export) Below the I/P Page 9721 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23934 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1959 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 5827 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 7954 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 17326 X306 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) Page 18476 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 9343 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 14716 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 10933 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 8280 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Page 23607 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 10415 View of the connector when released from the component. View of another type of Micro 64 connector. Page 4955 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 5112 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 15687 Wheel Speed Sensor (WSS) - Right Front (JH6/JH7) Wheel Speed Sensor (WSS) - Right Rear (JL4) Wheel Speed Sensor (WSS) - Right Rear (JL4) Wheel Speed Sensor (WSS) - Right Rear (JL4) Page 23863 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Body - Door Latches Freezes in Extreme Cold Front Door Latch: Customer Interest Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. Page 4067 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11148 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 13343 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 24757 Wiper Motor: Service and Repair Windshield Wiper System Module Replacement Windshield Wiper System Module Replacement Page 6227 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 22322 Seat Cushion: Service and Repair Front Seat Cushion Rear Frame Center Cover Replacement Front Seat Cushion Rear Frame Center Cover Replacement Page 5385 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 14966 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 4080 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Audio System - Static/Ignition Noise on AM Band Ignition Cable: Customer Interest Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Page 18466 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9472 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 4937 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Interior - Carpet Curling At Front Edge Carpet: All Technical Service Bulletins Interior - Carpet Curling At Front Edge TECHNICAL Bulletin No.: 09-08-110-002 Date: January 27, 2009 Subject: Carpet Curling at Front Edge (Install Velcro Fastener) Models: 2007-2009 Chevrolet Silverado 2007-2009 GMC Sierra Condition Some customers may comment that the carpet is curling at the top front edge (1). Cause The front edge of the carpet assembly may be folded before installation into the vehicle at the time of manufacture. After installation, the edge of the carpet may begin to curl due to the fold condition. Correction Important: Do not replace the carpet assembly. Use the following steps to correct the condition. 1. Clean the carpet backing and the dash pad surface with general purpose adhesive cleaner in the area where the Velcro is to be applied. 2. Install two 100 mm (3.90 in) long strips of Velcro loop material, GM P/N 12520273, to the dash pad as shown (1). 3. Install two 100 mm (3.90 in) long strips of Velcro hook material, GM P/N 12520271 to the corresponding area of the carpet assembly. 4. Apply firm pressure to the repair area to ensure that the adhesive backing on the Velcro bonds to the surface. Warranty Information Page 3435 Power Window Switch: Diagrams Window Systems Connector End Views Window Switch - Driver X1 (A31 -AN3/DL3) Window Switch - Driver X2 (A31 -AN3/DL3) Page 497 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 3263 Seat Position Sensor: Diagrams SIR Connector End Views Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) Page 20559 Page 16967 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 11216 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 12995 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Service and Repair Child Seat: Service and Repair Child Seat Restraint System Belt Bracket Replacement (Ext Cab/Crew Cab) Page 12905 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Page 2536 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21541 Page 2532 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 4.5 quarts (4.3 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Keyless Entry Antenna Replacement (Regular Cab) Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Regular Cab) Keyless Entry Antenna Replacement (Regular Cab) Page 9518 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 199 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 23908 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15658 Page 530 Page 17951 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 20518 Body Control Module (BCM) X3 Page 9324 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 22424 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 14219 9. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). 10. Install the inner bearing. Important: The rubber outer sealing rings of the oil seal must be driven into the wheel hub first. 11. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 12. Install the rotor, if necessary. 13. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Important: If the wheel hub assembly does not fully seat itself onto the axle shaft spindle and is removed, the wheel hub seal must be replaced. 14. Install the wheel hub to the axle housing. Page 11059 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 17232 GM Engineering is seeing an increase in HVAC control head and actuator warranty where the component is fully functional when received. The root cause of the failure is intermittent wiring connections at the right hand BEC. Specifically, poor terminal tension of the 5V reference or Low Reference terminals in the X4 connector. Refer to the table. After the fault is removed. the actuators recover once commanded. Correction DO NOT REPLACE THE CONTROL HEAD. Use the following information to diagnose this condition: Page 4029 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 244 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 17851 Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Page 18055 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 15292 Rear Brake Rotor Replacement (JH7) Rear Brake Rotor Replacement (JH7) Caution: Refer to Brake Dust Caution . Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent brake cleaner, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable. Removal Procedure Locations Steering Angle Sensor: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 15213 Front Brake Caliper Bracket Replacement (JD9, JF3, JF7) Front Brake Caliper Bracket Replacement (JD9, JF3, JF7) Page 18508 Refrigerant: Fluid Type Specifications Refrigerant System Capacities Page 7583 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 6513 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 10657 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis line. 12. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. 13. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister. 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (1). 16. Remove the fuel/EVAP line clip nut (2). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Page 16956 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Campaign - Roof Lighting Circuit Addition Spot Lamp: Recalls Campaign - Roof Lighting Circuit Addition Subject: Service Update for Inventory and Customer Vehicles-Missing Circuit for Optional Roof Mounted Light (Beacon)-Expires with Base Warranty # 07029 - (01/29/2007) Models: 2007 Chevrolet Silverado 1500 2007 GMC Sierra 1500 with Optional Roof Mounted Light (TRW & -YE9) THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN FOR ANY TYPE OF SERVICE AND WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to create a circuit for the optional roof mounted light on certain 2007 Chevrolet Silverado 1500 and GMC Sierra 1500 vehicles equipped with provisions for an optional roof mounted light (TRW & -YE9). On these vehicles, the circuit for the operation roof mounted light is missing. This service procedure should he completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Parts Information Parts required to complete this service update are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Tools Required J 38125 Terminal Repair Kit Page 781 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Important: * Always note the orientation of the relay. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Page 6600 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1487 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 2662 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Locations Power Seat Control Module: Locations Power Seat Component Views Driver Seat 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (AN3) Page 17470 Inspect how the IP branch to C202 is routed. Reroute the wiring as necessary to match the correct routing in the photo above. In order to route the IP harness branch correctly (behind the junction block-left I/P): Remove the cover from the junction block-left I/P, unseat the junction block from the bracket. Disconnect C202. Route the harness such that it lays between the goalposts of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. Make sure that the grey offset retaining clip (off of the IP branch going to C202) is seated into the hole in the dashmat or into the brown buddy clip (if present), securing the IP branch to the vehicle. If the harness is still in contact with a sharp edge or point of the park brake assembly, protect the harness by routing it away from the contact point and holding it there with tie straps, and/or covering the sharp edge with butyl tape. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5589 7. Remove the insulator (1) from the intermediate muffler assembly hanger and remove the muffler assembly. 8. If equipped with a 5.3L, or a 6.0L engine, perform the following steps. 9. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease removal. 10. With the aid of an assistant, remove the insulators (1, 2) from the front and rear muffler assembly hangers. Page 9107 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 1851 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 10355 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 6847 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 11010 Page 7654 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 11512 Page 7088 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Universal Joint Replacement - Nylon Injected Ring Universal Joint: Service and Repair Universal Joint Replacement - Nylon Injected Ring Universal Joint Replacement - Nylon Injected Ring Tools Required * J 9522-3 U Joint Bearing Separator * J 9522-5 U Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft as to which end is the transmission end and which end goes to the rear axle. 3. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1 1/8 in) socket. 4. In order to shear the plastic retaining ring on the bearing cup, place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 5. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue to press the bearing cup out of the yoke. 6. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 7. Mark the orientation of the slip yoke to the tube for proper reassembly. 8. Remove the cross from the yoke. 9. Remove the remaining universal joint parts from the yoke. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 10. Inspect the retaining ring grooves for plastic. 11. Inspect the bearing cup bores in the yoke ears for burrs or imperfections. 12. Clean the remains of the sheared plastic bearing retainers from the grooves in the yoke. 13. The sheared plastic may prevent the bearing cups from pressing into place and thus prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. Page 13001 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 6001 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test Circuit/System Verification Important: On the scan tool, the powertrain relay is referred to as the EC ignition relay. 1. Ignition ON, engine OFF, command the powertrain relay ON and OFF several times using the scan tool output control function. You should either hear or feel the relay click with each command. 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate on at least one test point of each fuse. ‹› If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data list. Circuit/System Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit and ground. ‹› If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 3. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 4. Verify that a test lamp illuminates between the relay coil B+ and ground. ‹› If the test lamp does not illuminate, test the relay coil B+ circuit for a short to ground or an open/high resistance. 5. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground or an open/high resistance. If the circuits test normal Page 24600 Windshield Washer Pump: Diagrams Wiper/Washer Connector End Views Windshield Washer Fluid Pump Page 8143 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 22083 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2853 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 13352 Control Module: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Control Module (TCM), Engine Side Page 24662 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 9289 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 12990 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 12966 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 23565 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 2701 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 8752 Body Control Module (BCM) X5 Adjustments Axle Bearing: Adjustments Wheel Bearing Adjustment Preliminary Inspection Important: Ensure the brakes are fully released and do not drag. Pull or push the tire at the top back and forth in order to test the wheel bearing play. * Use a pry bar under the tire as an alternative. * If the wheel bearing adjustment is correct, the movement will be barely noticeable. * If the movement is excessive, adjust the bearings. Adjustment Procedure Tools Required J 2222-C Wheel Bearing Nut Wrench 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the axle shaft. 3. Remove the hub adjuster nut retaining ring. 4. Remove the adjuster nut lock key. Page 11231 Page 6824 Transmission Position Switch/Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft Position Switch Replacement Page 9597 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 15665 Parking Brake Warning Switch: Diagrams Park Brake Switch Park Brake Switch Page 5010 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9767 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7782 Page 21518 Jack Stowage Cover Replacement Jack Stowage Cover Replacement Page 16343 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Page 11316 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 11368 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 10973 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 5921 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 21636 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 8899 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. HVAC - Automatic Control Module HVAC: Locations HVAC - Automatic HVAC Component Views HVAC Module 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P C4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Page 14253 11. Using the J 24427 installer (2) and the J 8092 handle (1), install the inner bearing cup into the wheel hub. 12. Install the inner bearing. Page 2097 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 532 Electrical - Various Rear Door Electrical Malfunctions Fuse: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6912 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 7248 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 3159 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 21818 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 12858 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10276 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 6865 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 15641 Page 11823 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 18486 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Page 19081 Seat Belt Retractor: Service and Repair Rear Seat Belt Retractor Replacement (Extended Cab) Rear Seat Belt Retractor Replacement (Extended Cab) Page 8644 4. Connect the engine wiring harness electrical connector (1) to the HO2S pigtail electrical connector. 5. Connect the CPA retainer. 6. Lower the vehicle. Page 8512 1. Install a NEW MAP sensor seal to the MAP sensor, if necessary. 2. Install the MAP sensor (2) to the upper intake manifold. Notice: Refer to Fastener Notice. 3. Install the MAP sensor bolt (1). Tighten the bolt to 10 N.m (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the MAP sensor. Page 22838 Page 6913 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 17864 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Page 9337 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 4065 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 5119 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 1446 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7332 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 5707 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 10257 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 11944 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 9876 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 4487 4. Align the keyway of the crankshaft balancer with the crankshaft balancer key. 5. Install the crankshaft balancer onto the end of the crankshaft. 6. Using J 23523-F, press the crankshaft balancer onto the crankshaft. Notice: Refer to Fastener Notice. 1. Install the J 23523-F plate and bolts onto the front of the crankshaft balancer. Tighten the bolts to 25 N.m (18 lb ft). 2. Install the J 23523-F forcing screw into the end for the crankshaft. 3. Install the J 23523-F bearing, the washer, and the nut onto the forcing screw. 4. Rotate the J 23523-F nut clockwise until the crankshaft balancer hub is completely seated against the crankshaft position sensor reluctor ring. 7. Remove the J 23523-F. 8. Install the crankshaft pulley and bolts. Finger tighten all bolts until snug in order to fully seat the pulley. 9. Tighten the bolts. Tighten the bolts to 58 N.m (43 lb ft). 10. Ensure that the crown of the crankshaft balancer washer (2) is faced away from the engine. Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 13807 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9861 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 2527 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 8536 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 11394 View of the connector when released from the component. View of another type of Micro 64 connector. Page 12751 Torque Converter Clutch Solenoid: Connector Views 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Page 19090 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove all loose objects from the front seats. 5. Disconnect the seat belt pretensioner connector. 6. Cut the seat belt pretensioner harness connector out of the vehicle, leaving at least 16 cm (6 in) of wire at the connector. 7. Strip 13 mm (0.5 in) of insulation from each of the connector wire leads. 8. Cut two 6.1 m (20 ft) deployment wires from a 0.8 mm (18 gage) or thicker multi-strand wire. These wires will be used for the seat belt pretensioner deployment harness. 9. Strip 13 mm (0.5 in) of insulation from both ends of the wires cut in the previous step. 10. Twist together one end from each of the wires in order to short the wires. Deployment wires shall remain shorted, and not connected to a power source until you are ready to deploy the seat belt pretensioner. 11. Twist together one connector wire lead to one deployment wire. 12. Inspect that the previous connections is secure. 13. Bend flat the twisted connection. 14. Secure and insulate the connection using electrical tape. Page 2059 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Locations Dimmer Switch: Locations Lighting Systems Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 13833 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Exhaust System - Rattle/Thud Noise On Left Turns/Bumps Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust System - Rattle/Thud Noise On Left Turns/Bumps TECHNICAL Bulletin No.: 09-06-05-004 Date: May 20, 2009 Subject: Rattle or Thud Type Noise During Left Turns or While Driving Over Bumps (Perform Repair as Outlined) Models: 2007-2009 Chevrolet Silverado 1/2 Ton 1500 Series (Including Hybrid) 2007-2009 GMC Sierra 1/2 Ton 1500 Series (Including Hybrid) Condition Some customers may comment on a rattle or thud type noise during left turns or while driving over bumps. Cause This condition may be caused by contact between the front exhaust hanger and the frame hanger. Correction Perform the repair below to eliminate the contact between the front exhaust hanger and the frame hanger. 1. Raise and support the vehicle. 2. Measure the clearance (1) between the front exhaust hanger and the frame hanger. There should be at least 8 mm (0.315 in) clearance. Witness marks may also be visible. - If the clearance is less than specified, proceed to step 3. - If the clearance is within specification, diagnose and repair using the information found in SI. 3. Grind or file the front exhaust hanger head until the remaining material measures 4 mm (0.157 in). 4. Lower the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Entertainment System - DVD Screen Off After Ign. Cycle DVD Player: All Technical Service Bulletins Entertainment System - DVD Screen Off After Ign. Cycle INFORMATION Bulletin No.: 06-08-44-035C Date: August 04, 2009 Subject: Rear DVD Screen Off After Ignition Key is Cycled (Nav and Non-Nav Radios) Operating Instructions Models: 2007-2009 Buick Enclave 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra (Crew Cab Only), Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2009 HUMMER H2, H2 SUT 2007-2009 Saturn OUTLOOK Supercede: This bulletin is being revised to add NAV radios and additional information. Please discard Corporate Bulletin Number 06-08-44-035B (Section 08 - Body & Accessories). Some customers may comment that the rear DVD screen will not turn back ON after an ignition key cycle. This is a normal operating characteristic and no repairs should be made to the DVD screen. Notice Some early build vehicles may operate in a different manner and may turn back on after an ignition key cycle. This operation may change when the vehicle's radio has been replaced or the software has been updated due to a service concern. Also, some customer's may compare their vehicle to an early built vehicle that is not operating to design intent. This bulletin is to advise that this is the design intent of the vehicle and no repair attempts should be performed to change this operation. Advise the customer to either: 1. Press the power (ON/OFF) button on the remote control to turn ON the DVD screen. 2. Eject and re-insert the disc into the radio. This method will restart the media from the beginning. 3. For NAV unit radios - press play on the CD/DVD tab. Disclaimer Page 18022 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 5686 Disclaimer Page 7347 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 16797 Page 10622 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 18501 Tighten the bolts to 4 N.m (35 lb in). 5. Connect the electrical harness and the ground connections. 6. Install the HVAC module drain hose. 7. Install the instrument panel carrier. 8. Install the upper intake manifold sight shield. 9. Install the battery. 10. Install the accumulator. 11. Install the surge tank outlet hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 12. Install the inlet heater hose to the heater core. Firmly push the quick connect onto the heater core pipe until you hear an audible click. 13. Fill the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 9056 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 2744 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Audio System - Difficult To Install Fixed Radio Antenna Antenna Mast: Technical Service Bulletins Audio System - Difficult To Install Fixed Radio Antenna INFORMATION Bulletin No.: 07-08-44-001F Date: June 15, 2010 Subject: Information on Difficult to Install Fixed Radio Antenna Mast Models: 2006-2011 Cadillac Escalade EXT 2005-2010 Chevrolet Cobalt 2006-2009 Chevrolet TrailBlazer Models 2006-2011 Chevrolet Avalanche, Colorado, Silverado (Classic and New Style) 2006-2009 GMC Envoy 2006-2011 GMC Canyon, Sierra (Classic and New Style) 2006-2010 Pontiac G5 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years, a graphic with accompanying text and additional text in the Parts Information Description. Please discard Corporate Bulletin Number 07-08-44-001E (Section 08 - Body and Accessories). - A design change was made to the antenna base and antenna mast starting in October 2005. The radio antenna base size increased from 6 mm (0.23 in) to 7 mm (0.27 in) for improved stability and radio reception. - There are two different design antenna masts available. The antenna masts can be distinguished by the outer bottom of the antenna mast. The first design antenna mast (1) will have a six-sided hex design and a 6 mm (0.23 in) inside diameter thread. The second design antenna mast (2) will have two flats on the outer mast and a 7 mm (0.27 in) inside diameter thread. - The second design antenna mast will have more resistance when installing due to the interference fit of the threads in the mast as identified by the arrows in the graphic. Note Before proceeding, verify that the mast and base stud are properly aligned. Page 16191 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 10588 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 3733 Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement (Non-HP2) Page 10396 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Entertainment System - DVD Monitor Display Inoperative Television / Monitor: All Technical Service Bulletins Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Exhaust System - Underbody Rattle/Clunk/Rumble Noise Exhaust Pipe: Customer Interest Exhaust System - Underbody Rattle/Clunk/Rumble Noise Bulletin No.: 07-06-05-003 Date: March 08, 2007 TECHNICAL Subject: Exhaust Pipe / Muffler Rumble, Rattle, Moan, Drone, Vibration Noise (Align Exhaust and Install New Exhaust Seals) Models: 2007 Chevrolet Silverado 1500 Series Only 2007 GMC Sierra 1500 Series Only Condition Some customers may comment on an underbody rattle/clunk/rumble noise. Cause This condition may be due to insufficient clearance between the exhaust and transmission crossmember. Correction Measure the clearance between the exhaust pipe and the transmission crossmember. If the clearance is between 15 mm-30 mm (0.59 in-1.18 in), this is not the cause of the customer's concern. Do not proceed with this bulletin. Continue to diagnose the customer's concern. If the clearance is less than 15 mm (0.59 in), realign the exhaust following steps 2-6. Disconnect the Y-pipe outlet from the exhaust muffler assembly. Loosen both the left and right exhaust manifold pipe nuts. It may be necessary to remove the right side 02 sensor to gain access to all the right side exhaust manifold nuts. The left exhaust MUST be torqued first. Tighten the left exhaust manifold pipe bolts in the sequence indicated in illustration "A" above. Tighten: Tighten the bolts to 50 N.m (37 lb ft). Monitor the clearance between the exhaust pipe and the transmission crossmember. It may be necessary to push up on the exhaust while tightening the right exhaust manifold nuts in order to achieve a minimum clearance of 15 mm (0.59 in). Page 17002 Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 12242 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 19809 Page 17100 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 15008 Control Module: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Control Module Replacement Page 17538 Not all of the effects or driver notifications listed above have been experienced. However, the different effects and driver notifications may be caused by one of the wires in the IP harness being chafed or cut. Components on different lines in the list above are in different circuits. Due to the cause of the condition, and the positions of the wires in the IP harness, it is unlikely that more than one circuit will be affected by the condition. Upon investigation, the technician may find several DTCs set as current or in history. The technician may also find one or more blown fuses in the IP and underhood fuse blocks. The potential fuses are listed below: 60 amp MBEC1 (# 72) (Underhood) 30 amp AMP (# 40) (Underhood) 15 amp RDO (# 41) (Underhood) 10 amp IPC (# 46) (Underhood) 15 amp AIRBAG BATT (# 51) (Underhood) 10 amp DSM (Left side of IP) Cause The condition may be caused by one of the wires in the IP harness being chafed or cut on the parking brake pedal assembly. Five areas of potential contact have been identified and are shown. Page 13552 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 4897 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 15945 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 22984 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 8928 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 11172 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 14042 Valve Body Spring and Bore Plug Chart (inch) Page 4033 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 13577 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 2854 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 6411 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Diagrams Steering Mounted Controls Assembly: Diagrams Secondary/Configurable Control Connector End Views Steering Wheel Control Switch Assembly - Left (K34/KA9) Steering Wheel Control Switch Assembly - Right (UK3) Page 1668 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 5924 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement Page 16204 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 11481 For vehicles repaired under warranty, use the table. Disclaimer Page 1224 Disclaimer Page 12305 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 23134 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 17953 Wheel Hub: Specifications Hub Nut ............................................................................................................................................... .................................................... 240 N.m (177 lb ft) Page 2186 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 8571 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 6641 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 11342 Page 23066 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 6198 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 10416 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 3972 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 10493 11. Install the J 44466-12 (2) and the J 44466-13 (1) to the metering body and tighten. 12. Install the J 44466-11, retainer, and J 44466-13 to the fuel feed pipe and tighten. 13. Obtain the J 41413, close the valve (2) on the tank (3), and remove the regulator assembly. 14. Install the J 44466-10 (5) to the J 41413 tank (3) 15. Connect the J 44466-10 hose (1) to the J 44466-12 (3). 16. Install the J 39021, the J 39021-210 and J 39021-301 (4) to the metering body electrical connector. 17. Adjust the amperage selector switch on J 39021 to 0.5 amps. Page 16448 X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) Page 5896 Instruments Nav. Radio Clock/Clock Tab Malfunctions Navigation System: All Technical Service Bulletins Instruments Nav. Radio Clock/Clock Tab Malfunctions Bulletin No.: 08-08-44-002 Date: February 15, 2008 TECHNICAL Subject: Navigation Radio Clock and/or Clock Tab Do Not Appear or Disappears Intermittently (Update Navigation Radio with New Software) Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008 HUMMER H2 with Radio RPO UVB or U3U Condition Some customers may comment that the clock and/or the clock tab does not appear on the navigation screen. Cause This condition may be caused by a software anomaly, which causes the clock and/or clock tab to disappear during the ignition key cycle. Correction DO NOT REPLACE THE NAVIGATION RADIO. Using the Tech 2(R), verify that the vehicle is equipped with one of the following radio part numbers: If the vehicle is not equipped with one of the following radio part numbers, disregard this bulletin. 15882766 15882767 15940102 15940103 25797978 25834072 Update the Navigation Radio's software to correct this condition. This software upgrade will also update some operating characteristics on the Navigation Radio. The following functions or displays may be affected: Inform the customer that stored destinations and radio presets may not be retained during programming. clock font size text color on light colored screens split screen icon to minimize the "Points of Interest" popup and "Exit" popup change driver locked out features when the vehicle is out of "Park" "back" button on street address entry screen for entering street number How to Obtain Nav Software Update Disc (P/N 25956121 - software version 0B92): Software discs are available through the GM Nav Disc Center. Dealers should retain the disc for use in repairing future vehicles. DO NOT give the software disc to the customer. Page 5609 Disclaimer Page 23087 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 4018 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 20835 Front Door Window Regulator: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Park/Turn Signal Lamp Bulb Replacement (Chevrolet) Turn Signal Bulb: Service and Repair Park/Turn Signal Lamp Bulb Replacement (Chevrolet) Park/Turn Signal Lamp Bulb Replacement (Chevrolet) Page 23906 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 2843 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 3141 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 22969 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 12533 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 11695 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Locations Yaw Rate Sensor: Locations Antilock Brake System Component Views Under the Front Seats 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) Page 14821 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or greater. 6. Remove the TCC PCS retaining bolt and retaining bracket. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Body - Door Latches Freezes in Extreme Cold Rear Door Latch: All Technical Service Bulletins Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. Page 967 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 13031 Page 16721 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 10688 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Notice: Refer to Fastener Notice. 4. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 N.m (80 lb in). 5. Install the fuel/EVAP line clip nut (2). Tighten the nut to 20 N.m (15 lb ft). 6. Remove the caps from the fuel and EVAP lines. 7. Connect the chassis EVAP line quick connect fitting to the EVAP canister. 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Page 21382 Page 17679 Notice: Refer to Fastener Notice. 2. Install a new pitman arm washer (2) and nut (1). Tighten the nut to 250 N.m (184 lb ft). 3. Remove the steering gear from the vise. 4. Install the steering gear. 5. Adjust the front toe. Page 19924 Page 13075 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 10164 Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the air cleaner outlet resonator from the MAF/IAT sensor. 3. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. Page 14046 Page 17584 Alignment: Description and Operation Camber Description Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Page 6174 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 13134 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 6249 Page 1610 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Page 6517 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 10981 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 23144 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 10811 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 8455 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Electrical - 'No Trailer Connected' Message On DIC Trailer Brake Control Module: Customer Interest Electrical - 'No Trailer Connected' Message On DIC TECHNICAL Bulletin No.: 09-05-22-004 Date: November 05, 2009 Subject: No "Trailer Connected" Message on Driver Information Center (DIC) at Startup When Trailer is Connected (Reprogram ITBCM) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Equipped with Integrated Trailer Brake (RPO JL1) Condition Some customers may comment that when they connect their trailer, with the engine off, and after they start the engine, the Trailer Connected message is not displayed on the DIC. With the engine running, if the trailer connector is cycled, the vehicle will detect the trailer and display Trailer Connected. This concern should only affect trailers equipped with trailer brakes on a single axle. Cause The trailer brake control system is only compatible with trailers equipped with electric trailer brakes. The system will not work or detect trailers equipped with any other types of brakes such as surge, air or electric-over-hydraulic trailer brake systems. When a trailer is connected, the Trailer Brake Control Module (TBCM) performs a test to determine if the trailer is equipped with electric trailer brakes. If the trailer wiring or electric trailer brake magnets have additional resistance (caused by poor connections, corrosion, improper splices, etc.), the TBCM may not be able to detect the trailer. Correction A revised calibration has been developed to address these issues. Reprogram the Integrated Trailer Brake Control Module (ITBCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Refer to Trailer Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 17985 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 7796 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 9203 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 13084 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 5580 Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Left Side Exhaust Manifold Heat Shield Replacement - Left Side (4.3L) Removal Procedure 1. Remove the spark plug wires. 2. Reposition the spark plug wires out of the way, if necessary. 3. Remove the exhaust manifold heat shield bolts and heat shield from the exhaust manifold. Installation Procedure Notice: Refer to Fastener Notice. 1. Position the exhaust manifold heat shield to the exhaust manifold and install the heat shield bolts. Page 880 Body Control Module: Locations Data Communication Component Views Behind the I/P 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) (Export) Below the I/P Torsion Bar and Support Assembly Replacement (Bushing Style) Torsion Bar: Service and Repair Torsion Bar and Support Assembly Replacement (Bushing Style) Torsion Bar and Support Assembly Replacement (Bushing Style) Tools Required J 36202 Torsion Bar Unloading/Loading Tool Removal Procedure Notice: Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Install the J 36202 to the adjustment arm and the crossmember. 3. Using the J 36202, increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut. Important: Mark the adjustment bolt and count the number of times that is required to remove the adjustment bolt. 4. Remove the adjustment bolt (3) and the adjust nut (4) from the crossmember (1). 5. Remove the J 36202, allowing the torsion bar to unload. 6. Remove the adjustment arm (2) by sliding the torsion bar forward. 7. Remove the torsion bar crossmember bolt (4) from the weld nut (1). Page 10757 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 6092 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 9757 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 694 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 508 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 16223 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 7568 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 17158 Junction Block - Right I/P X3 Page 9887 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 16043 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 10773 Page 5866 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 11786 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 13385 Disclaimer Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 5851 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 13850 Page 4813 For vehicles repaired under warranty, use the table. Disclaimer Page 5899 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 14106 If a condition is found, clean the area and repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Lost Communication With DTC's Set Lost Communication with Various Control Modules and DTCs Set DTC Descriptors Note Depending on the vehicle there may be other DTCs set by other modules. - DTC U0073 Control Module Communication Bus A Off - DTC U0100 Lost Communication with Engine/Powertrain Control Module (ECM/PCM) - DTC U0101 Lost Communication with Transmission Control Module (TCM) - DTC U0102 Lost Communication with Transfer Case Control Module - DTC U0121 Lost Communication with Electronic Brake Control Module (EBCM) - DTC U0140 Lost Communication with Body Control Module (BCM) 1. Connect a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). If any DTC(s) are set, refer to the list above or the Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. Turn OFF the ignition and all accessories. 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 4. Disconnect the connector(s) at the affected module. 5. Inspect the connector(s) for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) - Water intrusion ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI AND ‹› If corrosion or water intrusion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Reconnect the connector(s) at the affected modules. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Repairing Fretting Corrosion Repairing Fretting Corrosion Note Fretting corrosion looks like little dark smudges on the electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. 1. If any water intrusion is present in the connector, use pressure regulated compressed air to dry it out. 2. DO NOT apply an excessive amount of dielectric lubricant as shown, to the connectors as hydrolock may result when attempting to mate the connectors. Page 992 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 17324 Page 7342 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 9567 Page 16354 Disclaimer Page 24432 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Power) Rear Side Door Window Regulator Replacement (Crew Cab, Power) Locations Washer Fluid Level Switch: Locations Wiper/Washer Component Views Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Washer Fluid Level Switch 7 Windshield Washer Fluid Pump 8 - Air Cleaner Box Page 428 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 21072 Hood Hinge: Service and Repair Hood Link Replacement Hood Link Replacement Restraint System - Normal Safety Belt Locking Conditions Seat Belt: All Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Page 12381 Transmission Position Switch/Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Locations Knock Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 24578 Washer Fluid Heater: Service and Repair Windshield Washer Solvent Heater Replacement Page 20926 Rear Door Interior Handle: Service and Repair Rear Side Door Inside Handle Replacement (without SLT) Rear Side Door Inside Handle Replacement (without SLT) Page 24658 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 14099 - The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. - When releasing the park brake pedal, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. If a condition is suspected/found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202) or at any of these areas of concern then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Visually inspect the IP harness for damage at the park brake pedal assembly. Refer to potential damage points shown in the photos at the side and rear of the park brake assembly. Note that damage may be hidden from view. The harness may be turned away from you, or covered by electrical tape. 4. Operate the park brake release lever. Observe the moving part at the end of the park brake release cable as it may contact and damage the IP harness. Inspect the IP harness at this point. Note that the damage may be hidden from view by electrical tape. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. If the harness is still in contact with a sharp edge or point of the park brake assembly, route it away from the contact point and secure it with tie straps. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Service and Repair Wheel Cylinder: Service and Repair Wheel Cylinder Replacement Page 2242 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 15289 Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 22494 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 2375 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 23414 Page 18657 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 11701 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Hood Primary Latch Release Cable Handle Replacement Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Handle Replacement Hood Primary Latch Release Cable Handle Replacement Page 17156 Junction Block - Right I/P (Wire Entry) (Pin 2A1 To 4B6) Page 10807 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 18520 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Page 21934 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 233 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission: * The torque converter clutch solenoid (1) * The pressure control solenoid (2) * The internal wiring harness (3) * The 2-3 shift solenoid (4) * The 1-2 shift solenoid (5) * The transmission fluid pressure manual valve position switch (6) * The 3-2 shift solenoid (7) * The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wiring harness electrical connectors from the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) Page 24542 Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 14. After this procedure has been performed, issue a check to the customer or record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2006-2007 HUMMER H2 1. Open the hood and disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block in the engine compartment is located on the driver's side of the vehicle near the battery. Lift the cover for access to the fuse/relay block. Refer to Underhood Fuse Bock in the Owner's Manual for fuse information. 2. Locate the under-hood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer Mega fuse. 4. Remove the two nuts (1) for the Mega fuse (2). Refer to the picture. 5. Remove the 60 amp heated windshield washer Mega fuse. 6. Discard the 60 amp heated windshield washer Mega fuse. 7. Install the two nuts back into the two studs. 8. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 9 in this section of the bulletin. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. Page 12090 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 23007 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 628 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Communication Interface Module Replacement (without RPO SLT) Central Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Page 23024 Cruise Control: Scan Tool Testing and Procedures Scan Tool Data Definitions (Disengage History) Scan Tool Data Definitions (Disengage History) One of the following conditions must be present in order for a disengagement parameter to appear: * The Cruise Control System is active and disengagement is requested. * The engagement of the Cruise Control System is requested while a fault is present. Accel Rate - The engine control module (ECM) detects that the vehicle acceleration is greater than the calibrated cruise control threshold. APP Override - The ECM detects that the accelerator pedal overrides the set vehicle speed for approximately 60 seconds. Brake - The ECM detects that the stop lamps have been activated according to the brake pedal position (BPP) sensor / stop lamp switch input from the platform module. Also, the brake pedal being applied according to the brake fluid pressure sensor input can also set this disengagement reason with vehicles equipped with the vehicle stability enhancement system (VSES). BPP Data - The ECM detects an invalid brake pedal apply serial data message from the platform module. BPP DTC - The ECM detects that DTC P0703 is active. Cancel - The ECM detects that the cruise control cancel switch has been activated. Clutch - The ECM detects that the clutch pedal switch has been activated. Coast Disengage - When the ECM detects that the cruise set/coast signal is active and the throttle blade fully closes the cruise control system will disengage until the ECM detects that the set/coast signal is inactive. The cruise control system will then engage and set with the new vehicle speed. Coast Speed Low - The ECM detects that the Set/Coast switch is activated until the vehicle speed is below 37 km/h (23 mph). Cruise S/W - The ECM detects that a cruise control software execution error is present. Cruise Sw Data - A fault in the serial data circuit from the cruise control switch to the platform module is detected. Cruise Sw. Off - The ECM detects that the cruise On/Off switch was turned to OFF when the cruise control system was enabled. D Whl Spd Low - The ECM detects the driven wheels are at a slower speed than the non-driven wheels. D Whl Spd Hi - The ECM detects the driven wheels are at a faster speed than the non-driven wheels. Decel Rate - The ECM detects that the vehicle deceleration is greater than the calibrated cruise control threshold. DLC Override - The ECM detects that a DLC override has occurred. DTC Set - The ECM detects that a DTC has been set which affects the cruise control operation. Service and Repair Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement The Traction Control Switch is part of the Accessory Switch Assembly. To replace the Traction Control Switch please refer to Accessory Switch Replacement (without RPO SLT) Accessory Switch Replacement (with RPO SLT). Page 5239 Installation Procedure 1. Install the inlet heater hose. 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Important: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 7791 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 19319 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 5053 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 16481 X306 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) Page 2156 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 6631 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 12071 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 19680 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 21871 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 12668 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 5984 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 17938 8. Remove the crossmember (2) from the crossmember mount (3). 9. Remove the torsion bar from the crossmember. Important: The left and right torsion bars are different and are not interchangeable. 10. Remove the torsion bars from the vehicle. Installation Procedure 1. Position the torsion bar in the lower control arm. 2. Install the torsion bar in the crossmember (2) on the crossmember mount (3). Notice: Refer to Fastener Notice. 3. Install the torsion bar crossmember bolt (4) in the weld nut (1). Tighten the crossmember bolt to 95 N.m (70 lb ft). 4. Install the adjustment arm (2) in the crossmember (1). 5. Install the adjuster bolt (3) and the adjuster nut (4). 6. Install the torsion bar into the adjustment arm until the torsion bar is fully seated. 7. Install the J 36202 to the adjustment arm and the crossmember. 8. Using the J 36202, increase the tension on the adjustment arm to load the torsion bar. 9. Turn the adjuster bolt the same amount of turns as it took to remove it. Page 19814 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Page 181 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 4121 Junction Block - Left I/P X1 Page 18229 Instrument Panel Center Air Outlet Replacement (without RPO SLT) Instrument Panel Center Air Outlet Replacement (without RPO SLT) Page 3689 3. Install the drain plug. Tighten the plug to 25 N.m (18 lb ft). 4. Lower the vehicle. 5. Fill the engine with the proper capacity and quality of engine oil. Refer to Approximate Fluid Capacities. 6. Operate the engine, check for leaks, and oil pressure. Page 17861 Transmission Support Crossmember Replacement (2WD 2500 HD/3500) Transmission Support Crossmember Replacement (2WD 2500 HD/3500) Page 23301 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Electrical - Battery Goes Dead Overnight Body Control Module: Customer Interest Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 2467 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 6561 Manifold Pressure/Vacuum Sensor: Diagrams Engine Controls Connector End Views Manifold Absolute Pressure (MAP) Sensor Page 13367 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 9283 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12721 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Transmission Fluid Temperature Sensor Specifications Page 10315 Fuel injector restrictions, deposits can be cleaned on the vehicle using the following procedure. Under NO circumstances should this procedure be modified, changed or shortened. As a long term solution, and to prevent reoccurrence, customers should be encouraged to use Top Tier Detergent Gasoline. For further information on Top Tier detergent gasoline and fuel retailers, please refer to the following Corporate Bulletin Numbers: - 04-06-04-047G (U.S. Only) - 05-06-04-022D (Canada ONLY) Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent approved for use with General Motors fuel system components. Other injector cleaners may cause damage to plastics, plated metals or bearings. General Motors has completed extensive laboratory testing of GM Upper Engine and Fuel Injector Cleaner, and can assure its compatibility with General Motors fuel system components, as long as the cleaning procedure is followed correctly. Injector Cleaning Procedure The following tools, or their equivalent, are required: - CH-47976 Active Fuel Injector Tester (AFIT) - J 35800-A Fuel Injector Cleaner - J 37287 Fuel Line Shut-off Adapter - J 42964 Fuel Line Shut-off Adapter - J 42873 Fuel Line Shut-off Adapter - * One bottle of GM Upper Engine and Fuel Injector Cleaner, P/N 88861802 (in Canada, P/N 88861804) - * One bottle of GM Fuel System Treatment Plus, P/N 88861011 (in Canada, P/N 88861012) Active Fuel Injector Tester (AFIT- CH-47976) Some dealers may not have an Active Fuel Injector Tester (AFIT- CH-47976). Dealers can contact to order an AFIT- CH-47976. Dealers still can test the fuel injectors without an AFIT. Refer to Fuel Injector Diagnosis (w/ J 39021 or Tech 2(R)) in SI. Important As mentioned in the AFIT User Guide, vehicles that are not listed in the AFIT menu can still be tested with the AFIT. Depending on the model, it may be possible to enter the previous model year and proceed with testing using the DLC connection. If this is not possible on the model that you are working on, it will be necessary to use the direct connection method outlined in the AFIT User Guide (See Pages 17-31). General Motors recommends that the Active Fuel Injector Tester (AFIT) be used in testing fuel injectors. If the SI diagnostics do not isolate a cause for this concern, use the Active Fuel Injector Tester (AFIT - CH-47976) to perform an "Injector Test" as outlined in the AFIT User Guide. The AFIT "Injector Test" measures the flow characteristics of all fuel injectors, which is more precise when compared with the standard Tech 2(R) fuel injector balance test. As a result, the AFIT is more likely to isolate the cause of a P1174 DTC (for example: if it is being caused by a fuel injector concern). The CH-47976 (Active Fuel Injector Tester - AFIT) can also be used to measure fuel pressure and fuel system leak down. Also, as mentioned in the P1174 SI diagnosis, if the misfire current counters or misfire graph indicate any misfires, it may be an indicator of the cylinder that is causing the concern. Refer to Fuel Injector Diagnosis (w/CH-47976) in SI for additional instructions. Training (U.S.) To access the training video on AFIT, take the following path at the GM Training Website: 1. After logging into the training website, choose the link on the left side of the page titled "web video library." 2. Then choose "technical." 3. Next, within the search box, type in September course number "10206.09D. 4. This will bring up a link with this course. Scroll through to choose "feature topic." 5. At this point, the seminar can be chosen to view or the video related to the AFIT. Additional training is available from the training website. Please see TECHassist 16044.18T2 Active Fuel Injector Tester and also see 16044.14D1 GM Powertrain Performance for more information on GM Upper Engine and Fuel Injector Cleaner. Page 8233 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module 7 - Fuse Block - I/P Left Rear of the Chassis Frame Page 21567 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 14892 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 7634 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 9639 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 21805 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 5100 Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 11252 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 7058 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Instrument Panel Electrical Center or Junction Block Replacement - Left Side Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Left Side Instrument Panel Electrical Center or Junction Block Replacement - Left Side Page 14011 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Page 24435 Rear Door Window Regulator: Service and Repair Rear Sliding Window Regulator Replacement Rear Sliding Window Regulator Replacement Removal Procedure Important: The new rear sliding window regulator and cables are serviced as an assembly. 1. Cycle the rear sliding window to the halfway position. 2. Remove the rear lower garnish molding. Important: Use a suitable tool to lift upward on the rear sliding window stops (1) to remove. 3. Remove the rear sliding window stops (1). Page 22330 Front Seat Cushion Frame Replacement Page 8360 Serial Data Communication Enable Page 21542 Vehicle Zoning Strategy Truck Zoning Page 11974 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 24196 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Exhaust Manifold Replacement - Left Side Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Side Exhaust Manifold Replacement - Left Side (4.3L) Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the catalytic converter to exhaust manifold nuts (1). 3. Lower the vehicle. 4. Remove the exhaust manifold heat shield bolts and shield. 5. Remove the spark plugs. 6. Reposition the spark plug wires out of the way, if necessary. Page 4644 2. Install the oil filter. Refer to Engine Oil and Oil Filter Replacement. 3. Lower the vehicle. Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Disconnect the engine wiring harness electrical connector (4) from the crankshaft position (CKP) sensor. Page 7430 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Reposition the knock sensor sleeve (3) down, away from the knock sensor. 4. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. Page 4978 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 17900 Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Revised Shock Component/Spring Replacement Bulletin No.: 07-03-08-008 Date: October 31, 2007 SERVICE MANUAL UPDATE Subject: Revised Shock, Shock Component, and/or Spring Replacement Models: 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon Models This bulletin is being issued to revise the Shock, Shock Component, and/or Spring Replacement procedure in the Front Suspension sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Special Tools J 45400 Spring Compressor Removal Procedure Use only hand tools to perform the following service procedure. The following service procedure is to be performed after the strut assembly has been removed from the vehicle and installed in the appropriate tool. Install the shock absorber assembly in the J 45400. Page 23139 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 10338 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: Customer Interest Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Page 14554 Control Module: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Page 8004 Page 10921 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 11014 Page 10069 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9634 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: All Technical Service Bulletins Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2049 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 12438 Disclaimer Page 21779 Paint: Service Precautions Clearcoat/Ultraviolet Screeners Notice Clearcoat/Ultraviolet Screeners Notice Notice: Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect. Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 23143 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 1912 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 1993 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 16696 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 5878 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Notice: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Important: It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. 3. Disengage the engine wiring harness upper electrical connector retainer (2) and remove the connector (1) from the ECM. 4. Disengage the engine wiring harness lower electrical connector retainer (3) and remove the connector (4) from the ECM. Page 1940 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 11655 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 12962 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 1887 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.3L) Removal Procedure 1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Page 23234 Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 4729 Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 3. Remove the fuel pump/oil pressure sensor fitting, if necessary. Installation Procedure 1. If installing the old fitting, apply sealant to the threads of the fitting. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 2. Install the fitting until snug, if necessary. Notice: Refer to Fastener Notice. 3. Tighten the fuel pump/oil pressure sensor fitting. 1. Tighten the fitting to 15 N.m (11 lb ft). 2. Increase torque until the centerline of the fitting (1) is 50 degrees from the centerline of the crankshaft (2). Page 8078 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 21371 Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 10239 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 2295 Knock Sensor: Connector Views Engine Controls Connector End Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Lighting - Turn Signals Have Increased Flash Rate Body Control Module: All Technical Service Bulletins Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7821 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 3502 pressure should stabilize and remain constant. 1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 3. Remove the J 37287 and CH-48027. 4. Operate the vehicle within the conditions of the customers concern while monitoring the fuel trim and O2 parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 5. If the fuel system components test normal, refer to Symptoms - Computers and Control Systems. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms Engine Controls Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Fuel Injector Replacement * Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Page 14123 4. Release the wiring harness conduit from the retainers that secure it to the rear of the engine and at the top of the transmission bell housing. Note The engine intake manifold is shown removed to provide clarity. 5. Pull the wiring harness up gently at the rear of the engine (1) and inspect the wiring harness for chafed/shorted wiring (2). If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing (1) or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 7. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Chassis Body Mounts Left Side Frame Rail 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Page 2070 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 11929 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 6067 View of the connector when released from the component. View of another type of Micro 64 connector. Page 5520 18. Connect the engine wiring harness electrical connector (2) to the right rear HO2S electrical connector (1). 19. Install the right rear CPA retainer. 20. Install the right rear HO2S electrical connector clip to the engine harness clip (3). 21. Connect the right front HO2S electrical connector (5) to the engine wiring harness electrical connector (4). 22. Install the right front CPA retainer. 23. Install the transmission crossmember. 24. Position the oil pan skid plate and install the oil pan skid plate bolts, if equipped. Tighten the bolts to 28 N.m (21 lb ft). 25. Lower the vehicle. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 7550 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 9825 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Notice: Refer to Fastener Notice. 4. Install the VSS bolt (2). Tighten the bolt to 11 N.m (97 lb in). Page 19128 Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement Inflatable Restraint Vehicle Rollover Sensor Replacement Page 13149 Transmission Control Module (TCM) 80-Way Connector (Part 2) Page 9936 Page 12927 Page 14074 Tighten the bolt to 11 N.m (97 lb in). 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. Tighten the bolts to 11 N.m (97 lb in). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 12928 Page 3826 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Page 12131 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 12043 Shift Interlock Solenoid: Diagrams Shift Lock Control Connector End Views A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid Page 13010 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6343 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 9950 Transmission Position Switch/Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft Position Switch Replacement Page 9280 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 18219 Air Duct: Service and Repair Floor Air Outlet Duct Replacement - Right Side Floor Air Outlet Duct Replacement - Right Side Page 4312 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 24163 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 16139 Steering - Steering Wheel Off Center/Clunk When Turning Tie Rod: Customer Interest Steering - Steering Wheel Off Center/Clunk When Turning Bulletin No.: 07-02-32-008A Date: November 21, 2007 TECHNICAL Subject: Steering Wheel Off Center While Driving Straight, Clunk Noise While Turning, Early Front Tire Wear (Perform Torque to Tighten Analysis and Repair as Necessary) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series (1/2 Ton) Models Only Supercede: This bulletin is being revised to add additional conditions and update the correction information. Please discard Corporate Bulletin Number 07-02-32-008 (Section 02 - Steering). Condition Some customers may comment that the steering wheel is out of position (turned to the left or right) while driving straight ahead and/or a clunk noise while turning with early front tire wear. Cause The cause of condition may be due to the threaded joint between the inner tie rod and the rack loosening. Testing has shown it to be unlikely that the joint will unscrew (separate) during normal driving maneuvers, however the steering wheel alignment can be affected. Correction If the steering wheel is turned to the left while driving straight ahead, remove the right hand steering gear convoluted boot clamps. After exposing the tie rod connection to the rack bar, use a paint pen or marker and place an indexing mark from the tie rod to the rack bar. Check the "torque to tighten" on the tie rod to rack bar attachment by applying 50 N.m (37 lb ft) torque in a clockwise direction. Do not exceed this specification. Use of a 1-9/16" crowfoot is necessary. Hold the rack bar with a pipe wrench. If the steering wheel is turned rightward during the straight ahead driving, conduct the same analysis described above on the left hand tie rod. Inspect the inner tie rod and the rack bar for a change in position of the index mark with respect to each other. If any position change is observed, replace the steering gear. Please call a engineer to coordinate the return of the steering gear. Align the steering wheel and set toe. If no relative motion is observed between the tie rod and the rack bar during the 50 N.m (37 lb ft) "torque to tighten" analysis, do not replace any steering components. Reinstall the tie rod boot to the rack housing with a new crimp clamp, P/N 11562064. Align the steering wheel and set toe. In both cases, reuse the outer tie rod ends. Parts Information Warranty Information 4L60-E/4L65-E/4L70-E - Automatic Transmission Extension Housing: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Case Extension Assembly Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Place a drain pan under the vehicle. 4. Remove the propeller shaft. 5. Remove the transmission mount. 6. Remove the case extension bolts (1). 7. Remove the case extension (2). 8. Remove and discard the case extension O ring seal (3). Installation Procedure 1. Install a new case extension O ring seal (3). 2. Install the case extension (2). Notice: Refer to Fastener Notice. 3. Install the case extension bolts (1). Tighten the bolts (1) to 45 N.m (33 lb ft). 4. Install the transmission mount. 5. Install the propeller shaft. 6. Remove the drain pan and the transmission jack. 7. Lower the vehicle. 8. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Refer to Transmission Fluid Check. Page 10253 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 15799 2. Install the key into the ignition lock cylinder. 3. Align the ignition lock cylinder and install it into the ignition lock cylinder case. 4. Install the steering column shroud. 5. Install the knee bolster. 6. Enable the SIR system. Refer to SIR Disabling and Enabling. Page 6976 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 13265 Tighten the bolt to 11 N.m (97 lb in). 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. Tighten the bolts to 11 N.m (97 lb in). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 2378 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 9563 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 11152 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Locations Power Seat Motor Position Sensor: Locations Power Seat Component Views Driver Seat 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (AN3) Page 17167 Fuse Block - Underhood X2 Page 8782 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 3326 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 12558 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 16684 Page 22194 Page 9088 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 10304 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections Page 5585 Heat Shield: Service and Repair Exhaust Heat Shield Replacement - Dash Panel Exhaust Heat Shield Replacement - Dash Panel Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the exhaust heat shield nuts. 3. Remove both wheelhouse panels. 4. Remove the exhaust heat shield (1, 3) from the dash panel studs. 5. Remove the heat shield (1, 3) through the respective wheelwell. Installation Procedure 1. Install the heat shields (1, 3) through the respective wheelwell. 2. Install the exhaust heat shield (1, 3) to the dash panel studs. Notice: Refer to Fastener Notice. 3. Install the exhaust heat shield nuts. Tighten the nuts to 9 N.m (80 lb in). 4. Lower the vehicle. Page 13519 Page 3497 Fuel Pressure: Service Precautions Relieving Fuel Pressure Caution Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 10819 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 18509 Refrigerant: Service and Repair Refrigerant Recovery and Recharging Tools Required * J 43600 ACR 2000 Air Conditioning Service Center * J 45037 A/C Oil Injector Caution: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. Caution: For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Notice: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Notice: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. Notice: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. the J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, Refer to Refrigerant System Capacities. Page 13612 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 5074 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 9236 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 5777 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 112 Method 1 Method 2 Page 17636 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Page 10926 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6493 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 9628 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 8584 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2554 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 7104 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: All Technical Service Bulletins Park Assist System Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Page 19698 For vehicles repaired under warranty, use the table above. Disclaimer Page 14007 Page 18881 Warranty Information (Saab U.S. Models) Disclaimer Page 11267 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 7820 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 8470 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 9798 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 1114 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 13760 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 1045 Engine Control Module X1 (Pin 1 To 24) Page 501 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 8631 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Page 13756 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 12860 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 16455 X202 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Page 21609 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 17698 7. Remove the power steering pump seals (1, 4, 5). 8. Remove and clean the power steering fluid reservoir magnet (3). 9. Inspect the welch plug in the power steering pump (2). DO NOT REMOVE IT. If the welch plug is deformed or dislodged then replace the power steering pump (2). Assembly Procedure 1. Clean and install the power steering fluid reservoir magnet (3). 2. Install the power steering pump seals (1, 4, 5) to the power steering pump (2). 3. Connect the power steering fluid reservoir (1) and the power steering pump (2). 4. Install the power steering pump flow control valve spring (3) and the power steering pump flow control valve (2) to the power steering pump assembly (1). Page 12067 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 14081 6. Use the J 44247 to complete the seating of the retaining feet that lock the connector (1) into the transmission case. 7. Install the detent spring assembly (2) onto the control valve assembly. Confirm that the roller of the detent spring assembly rests on the detent lever (1). 8. Attach the IMS connector on the internal harness to the IMS. 9. Install 2 detent spring bolts (3). Tighten the bolts to 12 N.m (108 lb in). 10. Install the oil pan and transmission internal oil filter. 11. Connect the external wiring harness to the transmission main connector. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 12. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 7211 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 18737 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 16708 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Inflatable Restraint Front End Sensor Replacement (1500) Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement (1500) Inflatable Restraint Front End Sensor Replacement (1500) Page 17841 7. Remove the lower shock module bolts from the lower control arm. 8. Using the J 43631 and the J 45851, remove the lower ball joint from the steering knuckle. Page 8463 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 5459 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 2781 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 7158 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: All Technical Service Bulletins Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6898 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 18212 Recirculation Actuator Replacement Recirculation Actuator Replacement Page 1518 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Page 18625 Air Temperature Sensor - Lower Right Page 5384 Vehicle Zoning Strategy Truck Zoning Page 3094 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 15469 4. Connect the left rear park brake cable (1) to the intermediate cable equalizer bar (2). 5. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling. 7. Adjust the park brake. Refer to Park Brake Adjustment (Disc Brake) Park Brake Adjustment (Drum Brake). Parking Brake Rear Cable Replacement - Left Side (JH6, JH7) Parking Brake Rear Cable Replacement - Left Side (JH6, JH7) Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the left park brake cable from the intermediate cable connector (1) by drilling a 3 mm (1/8 in) hole through the dimple in the Procedures Steering Angle Sensor: Procedures Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 8887 Page 10077 1. Position and install the EVAP canister vent solenoid to the vehicle. 2. Slide the EVAP canister vent solenoid onto the bracket towards the driver side of the vehicle. 3. Ensure that the EVAP canister vent solenoid engages the fuel tank bracket retainer (1). Page 8963 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 2393 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 13851 Torque Converter Clutch Solenoid: Connector Views 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Page 23241 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 12983 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 8744 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 9007 Accelerator Pedal Position Sensor: Diagrams Engine Controls Connector End Views Accelerator Pedal Position (APP) Sensor Page 11088 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 4134 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Page 4146 Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Top View - Gas Fuse Block - Underhood, Bottom View Page 2784 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 7809 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 3113 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 3746 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Page 2485 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 22348 Rear Seat Cushion Outer Trim Panel Replacement (Extended Cab) Rear Seat Cushion Outer Trim Panel Replacement (Extended Cab) Page 13848 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 21626 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 16998 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 3128 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 7156 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 16894 Junction Block - Left I/P, Label Electrical Center Identification Views Junction Block - Left I/P, Label Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 1397 For vehicles repaired under warranty, use the table. Disclaimer Page 12210 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 11564 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 1926 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 20619 Front Door Exterior Handle: By Symptom Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9978 18. Connect the engine wiring harness electrical connector (2) to the right rear HO2S electrical connector (1). 19. Install the right rear CPA retainer. 20. Install the right rear HO2S electrical connector clip to the engine harness clip (3). 21. Connect the right front HO2S electrical connector (5) to the engine wiring harness electrical connector (4). 22. Install the right front CPA retainer. 23. Install the transmission crossmember. 24. Position the oil pan skid plate and install the oil pan skid plate bolts, if equipped. Tighten the bolts to 28 N.m (21 lb ft). 25. Lower the vehicle. Page 9666 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 11742 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 3249 Disclaimer Page 8541 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 17314 X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) Page 22694 Important Prior to attempting a repair of the vehicle, it will be necessary to compare it to a like vehicle in similar operating characteristics to determine if it should be considered normal operation or a repairable condition. 1. To properly diagnose the C-pillar body filler issue, complete the following steps: 1. Close the all doors and windows of the vehicle. 2. Without starting the vehicle, turn the vehicle ignition to the ON/RUN position. 3. Press the HVAC selector switch for Outside Air. 4. Turn the HVAC Fan Control to Medium/High. Note The air flow that is felt most commonly exits the lower C-pillar opening shown in the graphic above. 5. Run your hand alongside the lower seam of the body at the base of the C-pillar and feel for air flowing out of the bottom of the body. 6. Compare the air flow on the opposite side of the vehicle. If one side exhibits a distinct higher amount of air flow, continue on to the next step in this procedure to start the process of adding sealer to the C-pillar on that side. If no air flow difference is found, skip ahead to Correction #2. 2. To access the inner C-pillar, remove the rear seat and the body lock pillar trim panel. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Figure 1 - Outside View Through C-pillar Figure 2 - Top View, Section Cut Through C-pillar 3. Inspect the inner baffle/foam within the C-pillar for any voids in the body filler. The examples above show an opening (1) in the baffle at the forward, inboard corner of the right side C-pillar. Page 4021 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 14629 Transmission Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Turbine Speed Sensor Page 15820 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Page 13119 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. Page 15426 Brake Master Cylinder: Removal and Replacement Master Cylinder Reservoir Replacement (JD9, JF3, JF7) Master Cylinder Reservoir Replacement (JD9, JF3, JF7) Master Cylinder Reservoir Replacement (JH6, JH7) Page 9598 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 6773 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 7880 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 11133 Vehicle Zoning Strategy Truck Zoning Page 7044 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 14851 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 11142 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 10754 Fuel Tank Unit: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 14396 5. Install the propeller shaft (5) to the front axle pinion yoke (1). Align the reference marks made during removal. Notice: Refer to Fastener Notice. 6. Install the yoke retainers (7) and the bolts (6). Tighten the yoke retainer bolts to 25 N.m (18 lb ft). 7. Install the boot onto the transfer case output shaft until the boot snaps into the groove on the output shaft. 8. Using the J 43218 to crimp both clamps. 9. Lower the vehicle. Instruments - Compass/Temperature Display Information Compass: Technical Service Bulletins Instruments - Compass/Temperature Display Information INFORMATION Bulletin No.: 07-08-48-004A Date: June 13, 2008 Subject: Information on Outside Temperature and Compass Displays on Inside Rearview Mirror Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 with RPO DF5 or TQ5 (Intellibeam(R)) Inside Rearview Mirror Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin Number 07-08-48-004 (Section 08 - Body and Accessories). Some dealers/customers may notice that the outside temperature and compass are not displayed in the inside rearview mirror. The mirrors are usually turned on when the vehicles leave the assembly plant, but there may be situations when the mirrors may be turned off by the transport company, dealer personnel and/or the customer. If you experience a vehicle that has an inoperative compass and temperature display, make sure that the function is turned on in the mirror. Briefly press the on/off button on the left side of the mirror (RPO DF5) to turn the display on. The green LED that is on the left side of the mirror is for the automatic dimming function. There has been some confusion in which a customer sees the green LED and thinks that this automatically means the compass and the temperature display should be illuminated. So the customer may not try to turn the function on. If the vehicle is equipped with the Intellibeam(R) (RPO TQ5) mirror, press and hold the auto headlamp button on the left side of the mirror for 3-5 seconds. The Warranty Parts Center (WPC) has found that several of the mirrors were returned with the function turned off and there were no problems found with the mirror. Disclaimer Page 14156 2. Install the new rear axle housing cover bolts (1). Tighten the bolts to 40 N.m (30 lb ft). 3. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. 4. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 5. Lower the vehicle. Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. Page 960 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If vehicle is a 2-wheel drive (2WD) perform the following steps, otherwise proceed to step 5. 3. Disconnect the connector position assurance (CPA) retainer. 4. Disconnect the HO2S pigtail electrical connector (7) from the engine wiring harness electrical connector (6). 5. If vehicle is a 4-wheel drive (4WD) perform the following steps, disconnect the CPA retainer. 6. Disconnect the engine wiring harness electrical connector (7) from the HO2S pigtail electrical connector (8). Page 3201 Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Crew Cab +ASF) Page 1037 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 7619 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: All Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 4511 Notice: Refer to Fastener Notice. 4. Install the rocker arms as follows: 1. Finger start the bolt at location (1) 2. Finger start the bolt at location (2) 3. Finger start the bolt at location (3) 4. Finger start the remaining rocker arm bolts 5. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57-63 degrees clockwise or counterclockwise from the engine front cover alignment tab (2). Important: Once the rocker arms are installed and properly torqued, no additional valve lash adjustment is required. 6. Tighten the rocker arm bolts. Tighten bolts to 30 N.m (22 lb ft). 7. Install the rocker arm cover. Page 23792 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 8589 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 2647 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 5705 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 21813 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 4012 Page 14759 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Locations Ambient Light Sensor: Locations Lighting Systems Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 21899 Heated Seat References Diagrams Clockspring Assembly / Spiral Cable: Diagrams SIR Connector End Views Inflatable Restraint Steering Wheel Module Coil X1 Inflatable Restraint Steering Wheel Module Coil X2 Page 9387 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 6696 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer. 3. Disconnect the HO2S pigtail electrical connector (5) from the engine wiring harness electrical connector (4). 4. Remove the HO2S (2). Installation Procedure Page 1202 Air Bag Control Module: Diagrams SIR Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) (Extended/Crew Cab +10 Series +ASF) Page 6672 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 16272 Junction Block - Left I/P X2 (Pin E3 To P5) Junction Block - Left I/P X3 Page 190 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 12388 Transmission Position Switch/Sensor: Service and Repair Allison - Automatic Transmission Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Page 10463 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 1898 Page 14131 3. Push the main transmission connector (2) outward through hole (1) in the transmission case until the retaining feet on the connector are near the locked position. 4. Use J 44247 to seat the retaining feet on transmission connector (1). 5. Install the oil pan and transmission internal oil filter. 6. Connect the external wiring harness to the main transmission connector. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Page 8517 4. If installing the old sensor, apply sealant to the threads of the sensor. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 5. Using J 41712, install the sensor. Tighten the sensor to 30 N.m (22 lb ft). 6. Connect the fuel pump/oil pressure sensor electrical connector (3). 7. Check and adjust the engine oil level, if necessary. Page 13826 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 7259 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 7256 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 19976 Visually inspect and pull on the C2 Audio Amplifier Connector (1). If the connector is properly seated, then refer to SI for further diagnosis based on the customers condition. If the connector is loose, then reinstall the C2 Audio Amplifier Connector. Verify the connector is seated and locked into place. Install the fuses. Verify the condition has been fixed and clear any DTCs. If securing the connector does not correct the condition, refer to SI for further diagnosis and repair. Install the radio speaker amplifier assembly and any other components removed to gain access to the amplifier. Refer to Radio Speaker Amplifier Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 23121 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 6843 * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Page 8173 Engine Control Module X1 (Pin 1 To 24) Page 12863 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 8213 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 2443 4. Connect the engine wiring harness electrical connector (1) to the HO2S pigtail electrical connector. 5. Connect the CPA retainer. 6. Lower the vehicle. Page 5134 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 542 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 14911 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 16789 Page 18351 HVAC Control Module X3 Page 11096 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 8894 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 8009 4. Remove the CKP sensor bolt and sensor. Installation Procedure Important: When installing the CKP sensor, make sure the sensor is fully seated before tightening the bolt. A poorly seated CKP sensor may perform erratically and may set false diagnostic trouble codes (DTCs). Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CKP sensor, install a NEW O-ring seal onto the sensor. 2. Lubricate the O-ring seal with clean engine oil. Notice: Refer to Fastener Notice. 3. Install the CKP sensor and bolt. Tighten the bolt to 10 N.m (89 lb in). Page 2756 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 7644 Page 9759 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Page 23885 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 24637 Disclaimer Page 455 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 2730 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 9024 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 12676 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11047 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 6686 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice Silicon Contamination of Heated Oxygen Sensors Notice Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 24653 Page 16442 Multiple Junction Connector: Diagrams X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness X103 Page 2055 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 9850 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 1128 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 8935 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 21200 Page 22105 Page 13665 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 14296 18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 19. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 20. Dry all the parts. 21. Check the CV joint assembly for unusual wear, cracks, or other damage. 22. Replace any damaged parts. 23. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Procedure 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. Campaign - Roof Lighting Circuit Addition Marker Lamp: All Technical Service Bulletins Campaign - Roof Lighting Circuit Addition Subject: Service Update for Inventory and Customer Vehicles-Missing Circuit for Optional Roof Mounted Light (Beacon)-Expires with Base Warranty # 07029 - (01/29/2007) Models: 2007 Chevrolet Silverado 1500 2007 GMC Sierra 1500 with Optional Roof Mounted Light (TRW & -YE9) THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN FOR ANY TYPE OF SERVICE AND WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to create a circuit for the optional roof mounted light on certain 2007 Chevrolet Silverado 1500 and GMC Sierra 1500 vehicles equipped with provisions for an optional roof mounted light (TRW & -YE9). On these vehicles, the circuit for the operation roof mounted light is missing. This service procedure should he completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Parts Information Parts required to complete this service update are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Tools Required J 38125 Terminal Repair Kit Page 11524 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 16273 Junction Block - Left I/P X4 Page 5948 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 13987 Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Metric) Page 10174 Page 23219 Driver/Vehicle Information Display: Description and Operation Driver Information Center (DIC) Description and Operation The driver information center (DIC) displays the DIC WOW for 5 seconds when it first powers up. If enabled through Personalization, the DIC then returns to the last display status before no power condition. There are 4 switch functions for the DIC. * Personalization * Set/Reset * Trip/Fuel * Vehicle Info Trip/Fuel The Trip/Fuel switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Trip/Fuel switch * Accell Rate * Average Fuel Economy (AFE) * Average Vehicle Speed (AVE) * Fuel Range * Fuel Used * Instantaneous Fuel Economy (IFE)/ Displacement on Demand (DOD) * Maximum Speed * Odometer * Trans Temp * Trip A * Trip B * Trip Time Vehicle Info The Vehicle Info switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Vehicle Info switch. * Blank Display * English/Metric Units * Key Fob Programming Menu * Left Front Tire Pressure * Left Rear Tire Pressure * Oil Life Index (OLI) * Right Front Tire Pressure * Right Rear Tire Pressure * Tire Programming Menu Personalization The Personalization switch is used to set personalization features for both the vehicle and the driver. Many of the parameters in the Trip/Fuel menu and the Vehicle Info menu can be programmed through the Personalization switch. In addition to the parameters in the Trip/Fuel and Vehicle Info menus, the following features can also be programmed. * Approach Lighting * Automatic Door Lock * Automatic Door Unlock * Chime Volume * Delayed Door Lock * Display Language * Easy Exit Seat * Exit Lighting * Memory Seat Recall * Remote Door Lock * Remote Door Unlock * Remote Start Electrical - Multiple Electrical Concerns Wiring Harness: All Technical Service Bulletins Electrical - Multiple Electrical Concerns Bulletin No.: 07-08-49-018 Date: September 07, 2007 TECHNICAL Subject: Various Electrical Concerns - Intermittently Functioning or Inoperative Component, IP Warning Light On, DIC Message Displayed, DTC Set, No Crank/Start (Repair IP Wiring Harness) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on one of the driver notifications and/or effects shown above. Page 8243 Vehicle Zoning Strategy Truck Zoning Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) Axle Bearing: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) Tools Required * J 8092 Universal Driver Handle-3/4 in - 10 * J 21128 Axle Pinion Oil Seal Installer (8.6 inch and 9.5 inch LD Axles) * J 23690 Axle Shaft Bearing Installer (8.6 inch and 9.5 inch LD Axles) * J 2619-01 Slide Hammer * J 29709 Wheel Bearing Installer (9.5 inch Axle) * J 29712 Wheel Bearing Remover (9.5 inch Axle) * J 29713 Axle Seal Installer (9.5 inch Axle) * J 44685 Rear Axle Seal and Bearing Remover (8.6 inch and 9.5 inch LD Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch and 9.5 inch LD axles) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure Page 1658 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 9044 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Specifications Crankshaft: Specifications Crankshaft Connecting Rod Journal Diameter ......................................................................................................................... 57.116-57.148 mm 2.2487-2.2497 in Connecting Rod Journal Out-of-Round - Production ....................................................................................................................... 0.008 mm 0.0003 in Connecting Rod Journal Out-of-Round - Service ............................................................................................................................ 0.025 mm 0.0010 in Connecting Rod Journal Taper - Production .................................................................................................................................... 0.010 mm 0.0004 in Connecting Rod Journal Taper - Service ......................................................................................................................................... 0.025 mm 0.0010 in Crankshaft End Play ........................................................................................................................................................ 0.050-0.20 mm 0.002-0.008 in Crankshaft Main Journal Diameter #1 ................................................................................................................... 62.199-62.217 mm 2.4488-2.4495 in Crankshaft Main Journal Diameter #2 and #3 ....................................................................................................... 62.191-62.215 mm 2.4485-2.4494 in Crankshaft Main Journal Diameter #4 ................................................................................................................... 62.179-62.203 mm 2.4480-2.4489 in Crankshaft Main Journal Out-of-Round - Production ...................................................................................................................... 0.005 mm 0.0002 in Crankshaft Main Journal Out-of-Round - Service ............................................................................................................................ 0.025 mm 0.0010 in Crankshaft Main Journal Taper .......................................................................................................................................................... 0.007 mm 0.0003 in Page 15010 Page 19068 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9573 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 9722 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 20764 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Refer to Front Side Door Sill Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Plate Replacement (Extended Cab) . Page 11598 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid - A/T: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the catalytic converter. 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. Allison - Automatic Transmission Control Module: Service and Repair Allison - Automatic Transmission Transmission Control Module Replacement Page 11228 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 4141 Junction Block - Right I/P X5 Page 153 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 13810 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 8299 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 3339 Fluid Pressure Sensor/Switch: Service and Repair Allison - Automatic Transmission Pressure Switch Manifold Replacement Removal Procedure Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Caution: Refer to Battery Disconnect Caution. 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Page 8449 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 5282 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 16528 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 8375 Information Bus: Testing and Inspection Scan Tool Does Not Power Up Scan Tool Does Not Power Up Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using the diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Scan tool power battery positive voltage at terminal 16 * Scan tool power ground at terminal 4 * Common signal ground at terminal 5 Diagnostic Aids * The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. * If the battery positive voltage, ground circuits and connections of the DLC are functioning properly, the malfunction must be due to the scan tool/CANdi module. * Use the DMM MIN/MAX function to capture/locate intermittent conditions. Circuit/System Testing 1. Ignition ON, test for battery voltage between the battery positive voltage circuit of the DLC and ground. ‹› If less than battery voltage, repair the voltage supply circuit for a short to ground or an open/high resistance. 2. Test for less than 1 ohm of resistance between the ground circuit of the DLC and ground. ‹› If greater than 1 ohm, repair the ground circuit for an open/high resistance. 3. If all tests normal, refer to the scan tool/CANdi module user guide. Repair Instructions Perform the Diagnostic Repair Verification after completing the repair. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures Page 10388 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 3300 Steering Angle Sensor: Removal and Replacement Steering Wheel Position Sensor Replacement Page 11314 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Service and Repair Balance Shaft Bearing: Service and Repair Balance Shaft Bearing and/or Bushing Replacement Tools Required * J 26941 Bushing and Bearing Remover * J 38834 Balance Shaft Service Kit Removal Procedure Important: The balance shaft and the front bearing are serviced only as a package. Do not remove the bearing from the balance shaft. 1. Remove the balance shaft. 2. Using J 26941 and the J 38834, remove the balance shaft rear bearing. 1. Install the J 26941 legs behind the balance shaft rear bearing and secure. 2. Install the J 38834-1 with the short threaded end through the balance shaft bore in the front of the engine block. 3. Install J 38834-1 into the J 26941. 4. Slide the J 38834-2 onto the J 38834-1 and into the balance shaft bore of the engine block. 5. Install the J 38834 bearing, washer, and nut onto the J 38834-1. 6. Using a wrench, secure the J 38834-1, and then rotate the J 38834 nut clockwise until the balance shaft rear bearing is removed from the engine block. 7. Remove the J 26941 from the balance shaft rear bearing. 3. Discard the balance shaft rear bearing. Installation Procedure 1. Using J 38834, install the balance shaft rear bearing. 1. Install the J 38834-3 onto the short threaded end of the J 38834-1. 2. Install the J 38834 nut, the washer, and the bearing on the long threaded end of the J 38834-1. 3. Install the J 38834-2 onto the J 38834-1 so that the smaller diameter of the J 38834-2 will be facing the front of the engine block. 4. Install the J 38834-2 on the inside of the balance shaft front bearing bore. 5. Lubricate the NEW balance shaft rear bearing with clean engine oil. 6. Install the balance shaft rear bearing onto the J 38834-2. 7. Align the balance shaft rear bearing for installation. 8. Using a wrench, secure the J 38834-1 into place. 9. Rotate the J 38834 nut until the balance shaft rear bearing is properly and completely pushed into the balance shaft rear bearing bore. Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Side Door Window Regulator Motor Replacement (Crew Cab) Allison - Automatic Transmission Transmission Speed Sensor: Service and Repair Allison - Automatic Transmission Speed Sensor Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Page 23001 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Service Precautions Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Notice Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Page 5808 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 6718 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 5353 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 13238 Disclaimer Page 5057 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Recall - Heated Windshield Washer Module Short Circuit Technical Service Bulletin # 10153B Date: 100720 Recall - Heated Windshield Washer Module Short Circuit SAFETY Bulletin No.: 10153B Date: July 20, 2010 Subject: 10153A - Heated Windshield Washer Module Short Circuit - Permanently Disable and Remove Module Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2006-2009 HUMMER H2 2007-2009 Saturn OUTLOOK Equipped with Heated Washer Fluid System (RPO XA7/CHW) Supercede: This bulletin is being revised to include a note in the service procedure for dealers to confirm that the customer is aware that this safety recall is being performed on their vehicle prior to performing the repair. A T labor code for customers who refuse to have the recall performed. This labor code will NOT close the recall. If a customer refuses to have the recall performed, dealers are to provide the customer with a copy of the "Notice to Customer" document contained in this bulletin, record on the repair order "customer declined recall repair" and, if possible, have the customer sign the repair order. Request that the letter be placed in the vehicle glovebox for future reference by subsequent owners. If at a later date the customer, or a new owner, decides to have the recall performed, perform the repair and submit the claim using the appropriate V labor code. A clarification in the Q&A; regarding proof of vehicle ownership. Please discard all copies of bulletin 10153A, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (RPO XA7/CHW). A recall was implemented on some vehicles in 2008 to add a fuse to the HWFS control circuit harness to address the potential consequences of a printed circuit board electrical short. However, there have been new reports of thermal incidents on HWFS modules after this improvement was installed. These incidents resulted from a new failure mode attributed to the device's thermal protection feature. Their significance varies from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. Correction Dealers/retailers are to permanently disable and remove the heated washer fluid system and compensate the customer for the loss of the feature. Vehicles Involved Involved are certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (RPO XA7/CHW), and built within these VIN breakpoints: Electrical - No Start/No Crank/Int Electrical Operations Multiple Junction Connector: All Technical Service Bulletins Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 6640 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 4952 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Locations Sunroof / Moonroof Switch: Locations Sunroof Component Views Front Headliner Components 1 - Inside Air Temperature Sensor - Front (CJ2) 2 - Cellular Microphone (UE1/U3U/UVB) 3 Courtesy/Reading Lamps - Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade - Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly 8 - Inside Rearview Mirror (ISRVM) 9 - Courtesy/Reading Lamps - Front 10 - Windshield 11 - Sunshade - Left (DH6) Page 12124 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 1832 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 13636 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. Tighten the bolts to 12 N.m (108 lb in). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Page 16608 For vehicles repaired under warranty, use the table. Disclaimer Locations Headlamp Dimmer Switch: Locations Lighting Systems Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 1005 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 2598 Page 19107 1 - Lower Radiator Support 2 - Inflatable Restraint Front Sensor Under the Front Seats Page 15553 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 10100 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip (1) from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 12004 1. Ensure that the spark plug washer is positioned correctly. 2. Inspect the spark plug gap. Adjust the gap as needed. 3. Install the spark plug into the cylinder head by hand. (left side shown, right similar). Notice: Refer to Fastener Notice. 4. Tighten the spark plug. Tighten the plug to 15 N.m (11 lb ft). 5. If reinstalling the old spark plug wires, apply dielectric grease GM PN 12345579 (Canadian PN 10953481), or equivalent to the inside the spark plug wire boots. 6. Install the appropriate spark plug wire boot(s) (2) to the spark plug. (left side shown, right similar). Page 21203 Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required j 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the oil pressure sensor. Do not allow debris to enter the engine. 1. Disconnect the fuel pump/oil pressure sensor electrical connector (3). 2. Using J 41712, remove the fuel pump/oil pressure sensor. Page 18652 Solar Sensor: Service and Repair Sun Load Sensor Replacement Page 12023 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 2564 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Page 18120 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 24223 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 23903 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 17654 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. 3. Dismount the tire from the rim. Important: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 19930 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Diagrams Memory Positioning Module: Diagrams Power Seat Connector End Views Memory Seat Module X1 (AN3) Memory Seat Module X2 (AN3) Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 5343 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 8371 ‹› If greater than 1 ohm, repair the ground circuit for an open/high resistance. 5. Attempt to communicate with the electronic brake control module (EBCM). Communication should not be available. ‹› If communication is established, test or replace the resistor. 6. Ignition OFF, disconnect the harness connector of the suspension control module. 7. Attempt to communicate with the EBCM. Communication should not be available. ‹› If communication is established, test the serial data circuits for a short between them, short to ground or a short to voltage between the suspension control module and the terminator resistor. If the circuits test normal, replace the suspension control module. 8. Ignition OFF, disconnect the harness connector of the distance sensing cruise control module. 9. Attempt to communicate with the EBCM. Communication should not be available. ‹› If communication is established, replace the cruise control module. 10. Ignition OFF, disconnect the harness connector of the vehicle communication interface module (VCIM). 11. Attempt to communicate with the EBCM. Communication should not be available. ‹› If communication is established, test the serial data circuits for a short between them, short to ground or a short to voltage between the between the VCIM and the suspension control module. If the circuits test normal, replace the VCIM. 12. Ignition OFF, disconnect BCM harness connector C3. 13. Test for infinite resistance between the serial data circuits of BCM harness connector C3 terminal 8 and ground and between BCM harness connector C3 terminal 9 and ground. ‹› If less than infinite, test the circuit for a short to ground. 14. Ignition OFF, disconnect the harness connector of the ECM. Connect the harness connector C3 of the BCM. 15. Attempt to communicate with the EBCM. Communication should not be available. ‹› If communication is established, replace the ECM. 16. Ignition OFF, disconnect the harness connector of the transmission control module (TCM). 17. Attempt to communicate with the EBCM. Communication should not be available. ‹› If communication is established, test the serial data circuits for a short between them, short to ground or a short to voltage between the TCM and the ECM. If the circuits test normal, replace the TCM. 18. Ignition OFF, connect the harness connector of the suspension control module. Disconnect the harness connector of the EBCM. 19. Attempt to communicate with the suspension control module. Communication should not be available. ‹› If communication is established, test the serial data circuits for a short between them, short to ground or a short to voltage between the EBCM and the TCM. If the circuits test normal, replace the EBCM. 20. Ignition OFF, disconnect the harness connector C3 of the BCM. 21. Test for less than 1 volt between the high speed GMLAN serial data circuits of the DLC and ground. ‹› If greater than 1 volt, test the serial data circuit for a short to voltage. 22. Test for infinite resistance between the high speed GMLAN serial data circuit of the DLC and ground. ‹› If less than infinite resistance, test the serial data circuit for a short to ground. 23. Test for infinite resistance between the high speed GMLAN serial data (+) and (-) circuits of the DLC. ‹› If less than infinite resistance, test the serial data circuits for a short between them. 24. If the circuits test normal, replace the BCM. Repair Instructions Perform the Diagnostic Repair Verification after completing the repair. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures Page 9484 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 19282 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Page 6970 Page 5973 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 24693 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 4736 4. Install the balance shaft driven gear. 5. If reusing the fastener, apply threadlocker to the threads of the balance shaft driven gear bolt. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 6. Install the balance shaft driven gear bolt. 1. Use a wrench to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 2. Install the balance shaft driven gear bolt. 1. Tighten the bolt a first pass to 20 N.m (15 lb ft). 2. Tighten the bolt a final pass an additional 35 degrees using J 45059. 7. Remove the wrench from the balance shaft. 8. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case. 9. Install the balance shaft drive gear. DO NOT install the camshaft sprocket bolts at this time. 10. Rotate the camshaft so that the timing mark on the balance shaft drive gear is in the 12 o'clock position. Page 7417 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 12722 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 5681 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Diagrams Lateral Accelerometer: Diagrams Yaw Rate and Lateral Acceleration Sensor (JL4) Yaw Rate and Lateral Acceleration Sensor (JL4) M/T - Hydraulic Clutch Bleeding Procedure Improvement Clutch Hydraulic System: Technical Service Bulletins M/T - Hydraulic Clutch Bleeding Procedure Improvement Bulletin No.: 01-07-31-002B Date: November 01, 2006 INFORMATION Subject: Improved Bleeding Procedure for Hydraulic Clutch Release System Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2007 and Prior Chevrolet and GMC 6-7F T-Series Medium Duty Tilt Cab Models 2007 and Prior Isuzu F-Series Medium Duty Tilt Cab Models 2006-2007 HUMMER H3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-07-31-002A (Section 07 - Transmission/Transaxle). This bulletin is being issued to inform dealers of an improved procedure to aid in the ease of bleeding the clutch hydraulic system for the above listed vehicles. This procedure can be used anytime air is introduced into the hydraulic system. Following this procedure may also reduce the number of unnecessary parts replaced for low clutch pedal reserve and high shift effort. Verify that all the lines and fittings are dry and secure. Clean the dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system. Remove the reservoir cap. Fill the reservoir to the proper level with the required fluid. Attach the J 43485 (Adapter) to the J 35555 (Mity Vac), or equivalent. Brake fluid will deteriorate the rubber on J 43485. Use a clean shop cloth to wipe away the fluid after each use. Place and hold the adapter on the reservoir filler neck to ensure a tight fit. In some cases, the adapter will fit into the reservoir opening. Apply a vacuum of 51-68 kPa (15-20 hg) and remove the adapter. Refill the reservoir to the proper level. Repeat Steps 6 and 7. If needed, refill the reservoir and continue to pull a vacuum until no more bubbles can be seen in the reservoir or until the fluid level no longer drops. The vehicle will move if started in gear before the Actuator Cylinder is refilled and operational. Start the vehicle the first time in neutral to help prevent personal injury from vehicle movement and see if the transmission will shift easily into gear. Pump the clutch pedal until firm (to refill actuator cylinder). Add additional fluid if needed. Test drive vehicle to ensure proper operation. Disclaimer Page 16888 Junction Block - Right I/P, Top View Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 4258 Spare Tire: Service and Repair Spare Wheel Hoist Replacement Tire Hoist Secondary Latch Mechanism Important: If the spare tire hoist has been fully raised without a spare tire in place, the secondary latch mechanism may have become engaged. If this has occurred the hoist will not lower and the following steps will need to be followed: 1. Rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable (1) is exposed. 2. While holding the latch pin (3), fully depress the latch button (2) and release the secondary latch from the hoist assembly. Some side-to-side and/or up-and-down movement may be necessary to disengage the latch mechanism. 3. Continue rotating the hoist shaft counterclockwise in order to lower the hoist the rest of the way. 4. If this does not release the secondary latch, the spare tire hoist will need to be replaced. See the following procedure. Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and using the ignition key, remove the lock. Notice: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, replace the IPC. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Refer to Programming and Relearning for Control Module setup and programming. See: Testing and Inspection/Programming and Relearning * Instrument Cluster Replacement (without RPO SLT) Instrument Cluster Replacement (with RPO SLT) Page 12170 Tighten the bolt to 11 N.m (97 lb in). 6. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 9. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 10818 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 10398 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 4416 2. Place the AT in Park (P) or the MT in the lowest gear (1st). 3. Securely attach the vehicle being towed to the tow vehicle. Caution: Shifting the transfer case to Neutral can cause the vehicle to roll, even if the transmission is in park (automatic) or 1st gear (manual), and may cause personal injury. 4. If equipped, place the transfer case shift lever in Neutral (N). Note: Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 5. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 6. The Owner's Manual specifies the appropriate ignition key position to ensure that the steering is unlocked to allow the front wheels to follow the tow vehicle. Rear Wheel Drive Light Duty Trucks Important: ^ Dust or dirt can enter the back of the transmission through the opening created by the removal of the slip yoke from the transmission if proper protection is not provided. ^ Verify that the transmission fluid is at the proper level before driving the truck. Rear wheel drive vehicles, equipped with AT or MT, should NOT be dinghy towed. These transmissions have no provisions for internal lubrication while being towed. In order to properly tow these vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when it is unavoidable that a rear wheel drive vehicle be dinghy towed, the propeller shaft to axle yoke orientation should be marked and the propeller shaft removed. Refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Transfer Case Identification Page 659 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 1421 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Page 9738 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 882 Body Control Module: Diagrams Data Communication Connector End Views Body Control Module (BCM) X1 Page 16722 View of the connector when released from the component. View of another type of Micro 64 connector. Page 6089 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 10465 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 14739 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 2732 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 15196 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: All Technical Service Bulletins Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3653 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 23183 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 6858 Air Flow Meter/Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 3701 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. Page 2089 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 295 Power Door Lock Relay: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 15810 Disclaimer Page 7239 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Locations Power Seat Control Module: Locations Power Seat Component Views Driver Seat 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (AN3) Page 24741 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 23281 Parts Information Warranty Information For IP clusters replaced/programmed due to customer satisfaction concerns of poor backlighting, the warranty claim MUST be submitted using the labor operation listed in this bulletin. Disclaimer Page 5346 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Locations Shift Interlock Solenoid: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 11882 Page 11957 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 6221 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 6740 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 23228 Page 6735 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 24161 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 18712 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9098 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 6161 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 22488 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 20211 Page 11784 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 16927 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 2274 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 11508 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 16304 Fuse Block - Underhood X5 (Pin K4 To K8) Fuse Block - Underhood X6 Page 13627 Shift Solenoid 3 (SS3) Page 10197 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 18184 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Remove the wheel stud from the hub flange using the J 43631. 5. Remove the wheel stud from the hub flange. Installation Procedure 1. Install the new stud into the hub flange hole using firm hand pressure. 2. Install 4 washers to the new wheel stud. 3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange. 4. Tighten the lug nut until the stud contacts the back of the hub flange. 5. Remove the wheel nut. 6. Remove the washers. 7. Install the brake rotor. Tow Hook Replacement (1500/2500 Series) Towing Hook / Bracket: Service and Repair Tow Hook Replacement (1500/2500 Series) Tow Hook Replacement (1500/2500 Series) Page 11158 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 9316 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Interior - Poor Carpet/Rubber Mat Fit/Loose/Bulging Sound Proofing / Insulation: Customer Interest Interior - Poor Carpet/Rubber Mat Fit/Loose/Bulging Bulletin No.: 07-08-110-007B Date: November 30, 2007 TECHNICAL Subject: Front Floor Carpet or Rubber Floor Covering Poor Fit, Loose or Bulging (Install Floor Insulator/Deadener) Models: 2007-2008 Chevrolet Silverado Regular Cab 2007-2008 GMC Sierra Regular Cab with Carpet (RPO B30) or Rubber (RPO BG9) Floor Covering Supercede: This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin Number 07-08-110-007A (Section 08 - Body and Accessories). Condition Some customers may comment on the way the front floor carpet or rubber floor covering (1) fits on the center of the floor tunnel. Others may comment that the floor covering is loose, bulging or just fits poorly on the passenger side. Cause This condition may be caused by a lack of padding under the front floor carpet or rubber floor covering. Correction Install floor insulator/deadener to the top of the floor tunnel using the steps below. For vehicles equipped with a manual 4 x 4 shifter, the shifter knob and trim plate will need to be removed. Refer to Transfer Case Control Lever Replacement in SI. Remove the carpet or rubber floor covering away from the front floor tunnel. Refer to Floor Panel Carpet Replacement (Regular Cab) in SI. Tip The instrument panel (IP) support bracket will need to be removed by prying apart the two trim panels and removing the bolts. Page 13995 Important: 2008 Silverado or Sierra equipped with 6L90 (MYD) are built with this TCM calibration revision. 4. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. This new service calibration was released with TIS satellite data update version 7.5 or later, available July 22, 2007. As always, make sure your Tech 2(R) is updated with the latest software version. 5. After reprogramming the TCM, Service Fast Learn Adapts must be performed using the Tech2(R). Check and clear all DTCs that may have set as a result of the programming process. 2006-2008 Vehicles with a 6L50, 6L80 or 6L90 Transmission (MYB, MYC or MYD) (Except 2007 Silverado and Sierra w/6L90) 1. Inspect and note the transmission fluid level and condition. If the level is high or low, it should be corrected and the vehicle road tested to verify that the condition is still present. 2. Remove the transmission bottom pan to inspect for possible debris. ^ If debris is found, the transmission should be disassembled to determine the source. Repair or replace the transmission in the most economical method following guidelines in Corporate Bulletin # 02-07-30-029. ^ If no debris is noted in the oil pan, remove the control valve body assembly and proceed to the next step. 3. Disassemble the valve body to: ^ Inspect transmission filter for any cracks, holes or split seams that may allow air to be sucked into the pump. ^ Inspect the check balls for roundness ensuring that there are no flat spots. ^ Measure all the valve body bore plugs (328) for diameter. The specification is 11.502 mm +/0.004 mm. Undersize bore plugs should be replaced. ^ Inspect clutch select valve 2 (352) (Closest to the manual valve) in the lower valve body (351) for freedom of movement and travel. ^ Inspect CBR1/ C456 Reg Valve (327) in the upper valve body (321) for freedom of movement and travel. ^ Perform Control Solenoid Valve and Transmission Control Module Assembly Solenoid Performance Test (SI Document ID # 1618572) to determine if shift solenoid # 1 is functioning properly. Important: The seals included in plate kit, P/N 24236934 or 24238925, should be replaced when the valve body is assembled. Do not reuse the old seals. ^ Replace the spacer plate with the appropriate part number from the list below. This spacer plate makes use of a revised gasket to help reduce the occurrence of DTC P0751. This spacer plate is used in vehicles built November 17, 2007 or later. It will not resolve a DTC P0751 concern on a vehicle built November 17, 2007 or later. Parts Information Page 7286 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 16233 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 21846 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 23079 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 15374 Page 17318 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) Page 1008 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 21798 Door Module: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 7607 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 12667 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 10478 Page 12360 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Power and Grounding Component Views Fuse Block: Locations Power and Grounding Component Views Power and Grounding Component Views Left Side of the Engine Compartment 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (- MYC) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Engine Harness Jumper to Engine POA Harness Diesel Allison Transmission Fluid Checking Procedure Fluid - A/T: Testing and Inspection Allison Transmission Fluid Checking Procedure Transmission Fluid Check Cold Fluid Check The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made. Important: The fluid level rises as fluid temperature increases. DO NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures. 1. Bring the vehicle to a complete stop on a level surface using the service brakes. 2. Ensure that the engine is at low idle RPM (500-800 RPM). 3. With the service brakes applied, put the transmission in the P, PARK, position. 4. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 5. Apply the parking brake and ensure it is properly engaged. 6. Run the engine for at least one minute. Apply the service brakes and shift to D, DRIVE, then to N, NEUTRAL, and then shift to R, REVERSE, in order to fill the hydraulic system. 7. Ensure that the engine is at low idle RPM (500-800 RPM). 8. With the service brakes applied, put the transmission in the P, PARK, position. 9. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 10. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. Important: * If the fluid level is within the COLD CHECK band, the transmission may be operated until the fluid is hot enough to perform a HOT RUN check. If the fluid level is not within the COLD CHECK band, add or drain as necessary to bring it to the middle of the COLD CHECK band. * Always check the fluid level at least twice using the procedure described above. Consistent readings are important in order to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure that it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. Insert the fluid level indicator into the fill tube and remove. Check the fluid level reading. Repeat the check procedure to verify the reading. 11. Perform a hot check at the first opportunity after the normal operating sump temperature of 71-93°C (160-200°F) is reached. Hot Fluid Check Important: The fluid must be hot to ensure an accurate check. The fluid level rises as temperature increases. 1. Operate the transmission in D, DRIVE, range until normal operating temperature is reached. Normal operating temperature is any of the following: * Sump temperature 71-93°C (160-200°F) * Converter-out temperature 82-104°C (180-220°F) * If a transmission temperature gage is not present, check the fluid level when the engine water temperature gage has stabilized and the transmission has been operated under load for at least one hour. 2. Bring the vehicle to a complete stop on a level surface using the service brake. 3. Ensure that the engine is at low idle RPM, 500-800 RPM. 4. With the service brakes applied, place the transmission in the P, PARK, position. 5. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 6. Apply the parking brake and ensure it is properly engaged. 7. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. Important: Always check the fluid level at least twice using the procedure described above. Consistent readings are important to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. 8. Insert the fluid level indicator into fill the tube and remove. Check fluid level reading. Repeat the check procedure to verify the reading. Important: Safe operating level is within the HOT RUN band on the fluid level indicator. The width of the HOT RUN band represents approximately 1.0 liter (1.06 quarts) of fluid at normal operating sump temperature. 9. If the fluid level is not within the HOT RUN band, add or drain as necessary to bring the fluid level to within the HOT RUN band. Page 9824 Vehicle Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor (VSS) Page 1790 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 16302 Page 10193 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 16394 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Page 15577 Trailer Brake Control Module: Service and Repair Trailer Brake Control Relay Replacement Trailer Brake Control Relay Replacement Page 22195 Seat Back: Service and Repair Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement Page 6992 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Brakes - Aftermarket Trailer Brake Controllers Trailer Brake Control Module: All Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 21694 Driver Door Switch (DDS) X7 (AN3/DL3) Page 15734 15. Remove the negative battery cable from the vehicle. 16. If replacing the negative battery cable, remove the battery current sensor. Refer to Battery Current Sensor Replacement (4.3L) Battery Current Sensor Replacement (4.8L, 5.3L, 6.0L, and 6.2L). Installation Procedure 1. If the negative battery cable was replaced, install the battery current sensor. Refer to Battery Current Sensor Replacement (4.3L) Battery Current Sensor Replacement (4.8L, 5.3L, 6.0L, and 6.2L). 2. Install the negative battery cable to the vehicle. Page 16968 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 16966 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 8824 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 16874 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9105 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 16055 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 19230 - A wrench will be needed to install the antenna mast. When starting to thread the antenna mast onto the base stud, interference will be felt. The interference is similar to the feeling of a cross threaded fastener. Important Use a protective tape or a cloth inside an adjustable wrench when installing the antenna mast. This will help prevent damage to the painted coating on the antenna mast. - Tighten the antenna mast. Tighten Tighten to 6 Nm (53 lb in). Parts Information Disclaimer Page 2668 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 10734 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 11741 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 6972 Vehicle Zoning Strategy Truck Zoning Page 2671 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 4075 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 9596 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 17180 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Page 21868 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 7192 Page 3166 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 16134 Fuse: Application and ID Junction Block - Left I/P, Label Electrical Center Identification Views Junction Block - Left I/P, Label Page 12691 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 8043 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 23405 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice. 2. Install the park brake warning lamp switch bolt. Tighten the bolt to 3 N.m (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. 5. Connect the negative battery cable. Page 10194 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Entertainment System - DVD Screen Off After Ign. Cycle DVD Player: All Technical Service Bulletins Entertainment System - DVD Screen Off After Ign. Cycle INFORMATION Bulletin No.: 06-08-44-035C Date: August 04, 2009 Subject: Rear DVD Screen Off After Ignition Key is Cycled (Nav and Non-Nav Radios) Operating Instructions Models: 2007-2009 Buick Enclave 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra (Crew Cab Only), Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2009 HUMMER H2, H2 SUT 2007-2009 Saturn OUTLOOK Supercede: This bulletin is being revised to add NAV radios and additional information. Please discard Corporate Bulletin Number 06-08-44-035B (Section 08 - Body & Accessories). Some customers may comment that the rear DVD screen will not turn back ON after an ignition key cycle. This is a normal operating characteristic and no repairs should be made to the DVD screen. Notice Some early build vehicles may operate in a different manner and may turn back on after an ignition key cycle. This operation may change when the vehicle's radio has been replaced or the software has been updated due to a service concern. Also, some customer's may compare their vehicle to an early built vehicle that is not operating to design intent. This bulletin is to advise that this is the design intent of the vehicle and no repair attempts should be performed to change this operation. Advise the customer to either: 1. Press the power (ON/OFF) button on the remote control to turn ON the DVD screen. 2. Eject and re-insert the disc into the radio. This method will restart the media from the beginning. 3. For NAV unit radios - press play on the CD/DVD tab. Disclaimer Page 12089 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 8176 Engine Control Module X2 (Pin 31 To 73) Page 10192 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 8848 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 13574 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 12061 Vehicle Zoning Strategy Truck Zoning Page 10870 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 16731 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 23133 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 4214 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. 3. Dismount the tire from the rim. Important: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 5329 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 14328 1. Install the axle shaft bearing using the J 23690 (8.6 inch and 9.5 inch LD axles) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128 (8.6 inch and 9.5 inch LD axles) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 9. Lower the vehicle. Page 24178 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 21859 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 16733 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 4016 Page 12932 Page 21782 Paint: Application and ID Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. Use the service parts identification label to identify the type of paint technology, paint codes, trim level, and any special order paint colors on the vehicle. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label . Locations Ambient Temperature Sensor / Switch HVAC: Locations HVAC Component Views Ambient Air Temperature Sensors 1 - Radiator Core Support 2 - Ambient Air Temperature Sensor (DF5) 3 - Ambient Air Temperature Sensor - HVAC (CJ2) Page 3324 Fluid Pressure Sensor/Switch: Specifications Allison - Automatic Transmission Pressure Switch Manifold (PSM) Logic Pressure Switch Manifold (PSM) Logic Page 9192 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 11683 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 24210 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 17170 Fuse Block - Underhood X2 (Pin N1 To P5) Fuse Block - Underhood X3 Page 13616 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 22326 Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Page 24086 Turn Signal/Malfunction Switch X3 Page 9745 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Service and Repair Power Steering Pump Seal: Service and Repair Power Steering Pump Shaft Seal Replacement Removal Procedure 1. Remove the power steering pump from the vehicle. Important: Use the shim stock in order to protect the drive shaft. 2. Use a chisel in order to cut and remove the power steering pump shaft seal. Installation Procedure 1. Lubricate the new power steering pump shaft seal with power steering fluid. 2. Use a deep 1 inch tall socket in order to install the new power steering pump shaft seal. 3. Install the power steering pump. Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Page 12883 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 11073 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 4570 Step 1 - Step 7 Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 12103 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 8340 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 11444 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 13687 17. Install the clips on the cable to the floor panel reinforcement. 18. Lower the vehicle. 19. Test the transmission for proper shift operation. 20. If all of the gear positions cannot be achieved, adjust the cable. Range Selector Lever Cable Bracket Replacement Range Selector Lever Cable Bracket Replacement Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Remove the retainer that secures the cable to the bracket. 5. Depress the tangs and remove the cable from the bracket. 6. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. 7. Remove the transmission range selector cable bracket. Installation Procedure Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 16572 The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. When releasing the park brake pedal with the park brake release lever/handle, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. Correction If the symptoms match those listed above, or if a condition is found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202), then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: Visually inspect the IP harness for damage at the park brake pedal assembly (refer to potential damage points in photos - at the side and rear of the park brake assembly). Note that damage may be hidden from view (turned away from you, or covered by electrical tape). Operate the park brake release lever. Is the moving part at the end of the park brake release cable coming into contact and damaging the IP harness? Inspect the IP harness at this point. Note that the damage may be hidden from view (by electrical tape). If damage is found, repair the wiring. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 19821 Page 8163 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Classification Module - Air Bag: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 23622 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 5289 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 22515 Seat Heater: Scan Tool Testing and Procedures Scan Tool Data List Scan Tool Data List Scan Tool Data Definitions Scan Tool Data Definitions Memory Seat Module Driver or Passenger Seat HVC Mode - The scan tool displays the commanded state of the heated seat. Driver or Passenger Seat HVC Level - The scan tool displays the commanded state of the seat temperature setting during either of the heat modes. Driver and Passenger Door Switches Seat Heat High Ind. Cmd. - The scan tool displays the indicator command received from the memory seat module. Seat Heat Low Ind. Cmd. - The scan tool displays the indicator command received from the memory seat module. Seat Heat Medium Ind. Cmd. - The scan tool displays the indicator command received from the memory seat module. Seat Heat Mode Cmd. - The scan tool displays the seat heat mode indicator command received from the memory seat module. Seat Back Heat Mode Sw. - The scan tool displays the current state of the heated seat back switch input to the door module. Seat Heat Mode Sw. - The scan tool displays the current state of the heated seat switch input to the door module. Page 15478 Notice: Refer to Fastener Notice. 3. Install the park brake cable clip bolt (2). Tighten the bolt to 22 N.m (16 lb ft). 4. Connect the park brake cable (1) to the rear axle housing cover clip. 5. Install the park brake cable to the cable guides. 6. Connect the right rear park brake cable (1) to the intermediate cable equalizer bar (2). 7. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 8. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling. 9. Adjust the park brake. Refer to Park Brake Adjustment (Disc Brake) Park Brake Adjustment (Drum Brake). Parking Brake Rear Cable Replacement - Right Side (JH6, JH7) Locations Fuel Tank Pressure Sensor: Locations Engine Controls Component Views Near the Fuel Tank 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (- Diesel) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Line Pressure Sensor (-LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly - Front (Gas) Locations Accelerator Pedal Position Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 10717 8. Loosen the fuel tank fill pipe clamp (2) at the fuel tank. 9. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (1) from the fuel tank module. 10. Disconnect the vent tube attached at upper filler neck. 11. Remove the fuel tank fill pipe. 12. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure 1. Remove the cap from the opening on the fuel tank. 2. Install the fuel tank fill pipe. 3. Connect the vent tube to the upper filler neck. 4. Connect the fuel tank EVAP line quick connect fitting (1) to the fuel tank module. Notice: Refer to Fastener Notice. 5. Tighten the fuel tank fill pipe clamp (2) at the fuel tank. Page 2704 Air Flow Meter/Sensor: Connector Views Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 12566 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 11053 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 16120 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 16709 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 21552 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 18649 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 11446 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 515 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 11788 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 4344 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 6774 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 22678 Important Prior to attempting a repair of the vehicle, it will be necessary to compare it to a like vehicle in similar operating characteristics to determine if it should be considered normal operation or a repairable condition. 1. To properly diagnose the C-pillar body filler issue, complete the following steps: 1. Close the all doors and windows of the vehicle. 2. Without starting the vehicle, turn the vehicle ignition to the ON/RUN position. 3. Press the HVAC selector switch for Outside Air. 4. Turn the HVAC Fan Control to Medium/High. Note The air flow that is felt most commonly exits the lower C-pillar opening shown in the graphic above. 5. Run your hand alongside the lower seam of the body at the base of the C-pillar and feel for air flowing out of the bottom of the body. 6. Compare the air flow on the opposite side of the vehicle. If one side exhibits a distinct higher amount of air flow, continue on to the next step in this procedure to start the process of adding sealer to the C-pillar on that side. If no air flow difference is found, skip ahead to Correction #2. 2. To access the inner C-pillar, remove the rear seat and the body lock pillar trim panel. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Figure 1 - Outside View Through C-pillar Figure 2 - Top View, Section Cut Through C-pillar 3. Inspect the inner baffle/foam within the C-pillar for any voids in the body filler. The examples above show an opening (1) in the baffle at the forward, inboard corner of the right side C-pillar. Page 17742 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Page 18613 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Page 4878 Page 10619 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 4659 20. If equipped with 2WD, install the crossmember and bolts. Tighten the bolts to 100 N.m (74 lb ft). 21. Install the front differential carrier, if equipped with 4WD. 22. If equipped with 4WD, install the crossmember and bolts. Tighten the bolts to 100 N.m (74 lb ft). 23. If equipped, install the oil pan skid plate and bolts. Tighten the bolts to 20 N.m (15 lb ft). 24. Lubricate the oil filter gasket with clean engine oil. 25. Install the oil filter. Tighten the filter to 30 N.m (22 lb ft). 26. Lower the vehicle. 27. Fill the engine with the proper capacity and quality of engine oil. Refer to Approximate Fluid Capacities. Page 15052 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 10498 Fuel Injector: Removal and Replacement Fuel Injector Replacement Removal Procedure Important: The engine oil may be contaminated with fuel if the fuel injectors are leaking. 1. Remove the fuel meter body. 2. Remove the injector retainer lock nuts (4) and retainer (3). Notice: Use care in removing the fuel injectors to prevent damage to the electrical connector terminals. The fuel injector is serviced as a complete assembly only. Also since the injectors are electrical components, these injectors should not be immersed in any type of liquid solvent or cleaner as damage may occur. Fuel injector cleaning is not recommended. 3. While pulling the fuel injector downward, push with a small tip punch down between the injector terminals until the injector is removed. Installation Procedure Important: When ordering new fuel injectors, be sure to order the correct injector for the application being serviced. Page 5274 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 17320 Page 7395 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 17017 1 - Battery - Right 2 - Fuse Holder - Underhood 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 Fuse Block - Underhood 8 - X109 9 - Battery - Left (6A6/TP2) 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Fuse Block Jumper Harness (9L4) Page 6310 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Caster Description Alignment: Description and Operation Caster Description Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Page 17332 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Page 3264 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Page 13223 Fluid Line/Hose: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the front grill assembly. 2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. 3. Remove the transmission fluid cooler hose from the radiator. 4. Raise the vehicle. Refer to Vehicle Lifting. 5. Remove the engine protection shield. 6. Remove the cooling lines from the transmission. 7. Remove the oil cooling lines from the vehicle. Installation Procedure 1. Install the transmission oil cooler lines to the vehicle. 2. Install the cooling lines to the transmission. Page 3036 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 20640 Owner Letter Owner Letter July 2010 Dear GM Customer: As the owner of a 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, or Yukon XL vehicle, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles may have a peeling condition on the top surface of the front or rear chrome interior door handle(s) that could create a rough edge. A chrome plating irregularity combined with direct sunlight exposure may cause the plating to separate from the top surface of the handle. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners of 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles with additional protection for the front and rear chrome interior door handles. If this condition occurs on your 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, or Yukon XL within 10 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by July 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. Scott Lawson Director, Customer and Relationship Services Enclosure 09239 Page 4524 10. Align the hinge clip with the lip on the throttle body. In order to install the air cleaner outlet duct, pivot the air cleaner outlet duct downward until the mounting stud is through the hole. 11. Install the air cleaner adapter nut. Page 3893 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 10711 7. Position the chassis harness ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 8. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 N.m (80 lb in). 10. Lower the vehicle. 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 N.m (20 lb in). 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 N.m (20 lb in). Service and Repair Hood Latch: Service and Repair Hood Primary and Secondary Latch Replacement Page 5117 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 4877 Page 5324 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Front Side Door Inside Handle Replacement (with SLT) Driver/Vehicle Information Display: Description and Operation Driver Information Center (DIC) Description and Operation The driver information center (DIC) displays the DIC WOW for 5 seconds when it first powers up. If enabled through Personalization, the DIC then returns to the last display status before no power condition. There are 4 switch functions for the DIC. * Personalization * Set/Reset * Trip/Fuel * Vehicle Info Trip/Fuel The Trip/Fuel switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Trip/Fuel switch * Accell Rate * Average Fuel Economy (AFE) * Average Vehicle Speed (AVE) * Fuel Range * Fuel Used * Instantaneous Fuel Economy (IFE)/ Displacement on Demand (DOD) * Maximum Speed * Odometer * Trans Temp * Trip A * Trip B * Trip Time Vehicle Info The Vehicle Info switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Vehicle Info switch. * Blank Display * English/Metric Units * Key Fob Programming Menu * Left Front Tire Pressure * Left Rear Tire Pressure * Oil Life Index (OLI) * Right Front Tire Pressure * Right Rear Tire Pressure * Tire Programming Menu Personalization The Personalization switch is used to set personalization features for both the vehicle and the driver. Many of the parameters in the Trip/Fuel menu and the Vehicle Info menu can be programmed through the Personalization switch. In addition to the parameters in the Trip/Fuel and Vehicle Info menus, the following features can also be programmed. * Approach Lighting * Automatic Door Lock * Automatic Door Unlock * Chime Volume * Delayed Door Lock * Display Language * Easy Exit Seat * Exit Lighting * Memory Seat Recall * Remote Door Lock * Remote Door Unlock * Remote Start Page 22687 The outline portion (1) of the insulator should Only be removed if the vehicle is equipped with the manual 4x4 shifter. All other vehicles should use the complete piece. Remove the two protective paper strips (1) from the insulator. Attach the glue side of the insulator to the top of the floor tunnel as shown in the above illustration. Reposition the carpet or rubber floor covering back down into position. Install the body lock pillar trim panels. Refer to Body Lock Pillar Trim Replacement in SI. Install the jack and the jack handle kit. Refer to Jack Stowage Cover Replacement in SI. Install the IP support bracket, bolts and trim covers. Tighten Page 22572 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 20416 Trailer Connector: Diagrams Power and Grounding Connector End Views Trailer Connector (UY7) Door Lock and Side Window Switch Replacement - Driver Side Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Page 16007 Fuse: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 15854 Page 10441 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 7860 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 5884 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test Circuit/System Verification Important: On the scan tool, the powertrain relay is referred to as the EC ignition relay. 1. Ignition ON, engine OFF, command the powertrain relay ON and OFF several times using the scan tool output control function. You should either hear or feel the relay click with each command. 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate on at least one test point of each fuse. ‹› If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data list. Circuit/System Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit and ground. ‹› If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 3. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 4. Verify that a test lamp illuminates between the relay coil B+ and ground. ‹› If the test lamp does not illuminate, test the relay coil B+ circuit for a short to ground or an open/high resistance. 5. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground or an open/high resistance. If the circuits test normal Page 2201 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 12712 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 793 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 2960 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 1573 3. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 5. Install the axle shaft seal using the J 21128. 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. 8. Install the rear axle housing cover. 9. Install the rear wheel speed sensor. 10. Install the tire and wheel assembly. 11. Fill the rear axle. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 12. Lower the vehicle. Page 2633 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab Existing Motor) Re-Initialization/Teach Procedure (Manual Method), possible Re-Installation Perform the initialization/teach procedure at the first operation test of the sunroof. Ensure the electrical harness on the headliner is connected to the large roof, battery power is applied and the ignition switch is on. 1. Press the sunroof switch to the VENT OPEN position until the window reaches the vent open soft stop position and release. Press the sunroof switch - vent open and hold for approximately 10 seconds, until the window stalls at the front hard stop in the vent open position, and then moves slightly to the soft stop position. Release the button. (This is the re-initialization portion.) Continue with steps 2-4. 2. Within 3 seconds, press and hold the sunroof switch-vent open again. The sunroof window will move toward and past the flush position. (This is the teach portion.) 3. Continue holding the switch until the sunroof window moves to full open and then back to close and stops at the closed position. Release the button. The initialization/teach procedure is complete. 4. Verify the operation of the roof. The initialization/teach procedure is not completed if one of the following events occurs before the initialization/teach cycle is finished: * The sunroof switch is not held in the VENT OPEN position. * Ignition and/or battery power has been removed. * Glass panel has not reached the CLOSE position. If the initialization/teach procedure is not carried out completely, it must be started again. Page 16955 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18726 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 14807 Page 20913 5. Install the new roll pin that is included in the door handle kit, P/N 88880051. 6. Install the rear side door inside handles. Refer to Rear Side Door Inside Handle Replacement in SI. Customer Information 1. Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition covered under this Special Coverage are to be submitted to the dealer prior to or by July 31, 2011. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Page 6519 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 1969 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 6505 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 19992 Automatic Volume Control: Service and Repair Rear Seat Audio Control Replacement Specifications Engine Oil Pressure: Specifications Oil Pressure - at 1,000 RPM ................................................................................................................ ............................................................ 42 kPa 6 psi Oil Pressure - at 2,000 RPM .............................. ........................................................................................................................................... 125 kPa 18 psi Oil Pressure - at 4,000 RPM ..................................................................................................... .................................................................... 166 kPa 24 psi Page 17716 Power Brake Booster Inlet Hose Replacement Removal Procedure 1. Remove the engine shield. 2. Place drain pans under the vehicle as needed. 3. Remove as much power steering fluid from the power steering fluid reservoir as possible. Notice: Refer to Power Steering Hose Disconnected Notice. 4. Disconnect the power brake booster inlet hose from the power steering pump (3). 5. Disconnect the power brake booster inlet hose (1) from the power brake booster (2). 6. Remove the power brake booster inlet hose (1) from the vehicle. Installation Procedure Notice: Refer to Installing Hoses Without Twists or Bends Notice. 1. Install the power brake booster inlet hose (1) to the vehicle. Notice: Refer to Fastener Notice. Important: Start both power brake booster inlet hose fittings by hand before finalizing torques. 2. Connect the power brake booster inlet hose (1) to the power brake booster (2). Tighten the fitting to 32 N.m (24 lb ft). 3. Connect the power brake booster inlet hose (1) to the power steering pump (3). Tighten the fitting to 32 N.m (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Install the engine shield. 6. Fill and bleed the power steering system. Power Brake Booster Outlet Hose Replacement Power Brake Booster Outlet Hose Replacement Page 613 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 23646 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 22389 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 10427 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 13771 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 7132 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 9029 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 8246 Page 23562 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 24747 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 12239 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 17646 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 22413 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Interior - Carpet Curling At Front Edge Carpet: Customer Interest Interior - Carpet Curling At Front Edge TECHNICAL Bulletin No.: 09-08-110-002 Date: January 27, 2009 Subject: Carpet Curling at Front Edge (Install Velcro Fastener) Models: 2007-2009 Chevrolet Silverado 2007-2009 GMC Sierra Condition Some customers may comment that the carpet is curling at the top front edge (1). Cause The front edge of the carpet assembly may be folded before installation into the vehicle at the time of manufacture. After installation, the edge of the carpet may begin to curl due to the fold condition. Correction Important: Do not replace the carpet assembly. Use the following steps to correct the condition. 1. Clean the carpet backing and the dash pad surface with general purpose adhesive cleaner in the area where the Velcro is to be applied. 2. Install two 100 mm (3.90 in) long strips of Velcro loop material, GM P/N 12520273, to the dash pad as shown (1). 3. Install two 100 mm (3.90 in) long strips of Velcro hook material, GM P/N 12520271 to the corresponding area of the carpet assembly. 4. Apply firm pressure to the repair area to ensure that the adhesive backing on the Velcro bonds to the surface. Warranty Information Page 4953 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 1789 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 21605 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 12893 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 23954 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 16190 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 21217 1. Position the hitch platform to the vehicle. Notice: Refer to Fastener Notice . 2. Install the hitch platform bolts (6) to the frame weld nuts (2). Tighten the bolts to 100 N.m (74 lb ft). 3. Install the bolts (1) and nuts (7) securing the hitch platform to the frame rails. Tighten the nuts to 113 N.m (83 lb ft). 4. Install the hitch platform bolts (5) to the bumper weld nuts (4). Tighten the bolts to 100 N.m (74 lb ft). Page 2023 Crankshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 24705 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Door Striker Replacement (Crew Cab) Rear Door Striker: Service and Repair Door Striker Replacement (Crew Cab) Door Striker Replacement (Crew Cab) Removal Procedure Important: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer, if equipped, away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt (1). 5. Remove the spacer, if equipped. 6. Remove the striker (2). Installation Procedure Page 23920 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 10198 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9444 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 22540 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 9279 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 736 Parts Information Warranty Information For IP clusters replaced/programmed due to customer satisfaction concerns of poor backlighting, the warranty claim MUST be submitted using the labor operation listed in this bulletin. Disclaimer Interior - Wear Spots On Vinyl/Rubber Floor Covering Carpet: Customer Interest Interior - Wear Spots On Vinyl/Rubber Floor Covering TECHNICAL Bulletin No.: 08-08-110-013 Date: August 18, 2008 Subject: Premature Wear or Worn Spots on Rubber/Vinyl Floor Covering (Replace Floor Covering) Models: 2007-2009 Chevrolet Silverado, Silverado HD, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra HD, Yukon, Yukon XL with Rubber Floor Covering (RPO BG9) Including Police (RPO PPV) and Municipal (RPO 5W4) Vehicles EXCLUDING Standard and Crew Cab Models Condition Some customers may comment on premature wear or worn spots (1) on the front rubber/vinyl floor covering. Correction Important: The standard and crew cab models already have the updated floor mat material. Replace the affected floor covering. Refer to Floor Panel Carpet Replacement in SI. The mat floor covering material has been updated to reduce premature wear. Parts Information Page 6630 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 3377 For vehicles repaired under warranty, use the table. Disclaimer Allison - Automatic Transmission Transmission Mode Switch: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Transmission Internal Mode Switch Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 5992 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 6188 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 4153 Fuse Block - Underhood X4 Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 17426 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 13852 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control Solenoid 1 (PCS1) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Page 15356 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Notice: Refer to Fastener Notice. 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 N.m (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Rear Brake Caliper Overhaul (JH6, JH7) Rear Brake Caliper Overhaul (JH6, JH7) Page 12512 Shift Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 17391 X502 Left Front Door Harness to Body Harness (ASF+AN3/-YE9) X600 Inline Harness Connector End Views X600 Right Front Door Harness to Body Harness (YE9 -AN3/DL3) Page 16074 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 7594 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 200 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 4548 Disclaimer Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 17865 Transmission Support Crossmember Replacement (4WD 2500 HD/3500) Transmission Support Crossmember Replacement (4WD 2500 HD/3500) Page 21577 View of the connector when released from the component. View of another type of Micro 64 connector. Page 9922 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 22192 Page 17076 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 7955 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Instruments Nav. Radio Clock/Clock Tab Malfunctions Clock: Customer Interest Instruments Nav. Radio Clock/Clock Tab Malfunctions Bulletin No.: 08-08-44-002 Date: February 15, 2008 TECHNICAL Subject: Navigation Radio Clock and/or Clock Tab Do Not Appear or Disappears Intermittently (Update Navigation Radio with New Software) Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008 HUMMER H2 with Radio RPO UVB or U3U Condition Some customers may comment that the clock and/or the clock tab does not appear on the navigation screen. Cause This condition may be caused by a software anomaly, which causes the clock and/or clock tab to disappear during the ignition key cycle. Correction DO NOT REPLACE THE NAVIGATION RADIO. Using the Tech 2(R), verify that the vehicle is equipped with one of the following radio part numbers: If the vehicle is not equipped with one of the following radio part numbers, disregard this bulletin. 15882766 15882767 15940102 15940103 25797978 25834072 Update the Navigation Radio's software to correct this condition. This software upgrade will also update some operating characteristics on the Navigation Radio. The following functions or displays may be affected: Inform the customer that stored destinations and radio presets may not be retained during programming. clock font size text color on light colored screens split screen icon to minimize the "Points of Interest" popup and "Exit" popup change driver locked out features when the vehicle is out of "Park" "back" button on street address entry screen for entering street number How to Obtain Nav Software Update Disc (P/N 25956121 - software version 0B92): Software discs are available through the GM Nav Disc Center. Dealers should retain the disc for use in repairing future vehicles. DO NOT give the software disc to the customer. Page 3488 4. Set the top edge of the level on the reference surface of the steering knuckle (C) and extend the level directly under the rear end of the front attachment bolt of the lower control arm (A). 5. While keeping the level in contact with the knuckle reference surface, adjust the level up/down until the bubble indicates it is horizontally level. 6. Extend a tape measure straight down from the center of the attachment bolt. The point where the tape measure and the level intersect is your first measurement. 7. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the front end of the rear attachment bolt of the lower control arm (B). 8. Extend a tape measure straight down from the center of he attachment bolt. The point where the tape measure and the level intersect is your second measurement. 9. Push the front bumper of the vehicle down about 38 mm (1.5 in) 10. Gently remove your hands and let the vehicle settle. 11. Repeat this operation 2 more times for a total of 3 times. 12. Re-measure the Z height. 13. The true Z height is the average of the measurements taken. Refer to Trim Height Specifications. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Z Height Adjustment 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion arm as needed. One revolution of the bolt (1) into the nut increases the Z height by approximately 6 mm (0.2 in). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. 3. If these measurements are still out of specifications after adjustment or are not equipped with torsion bars, inspect for the following: * Sagging front suspension-Refer to Torsion Bar and Support Assembly Replacement (Bushing Style). * Collision damage Page 11717 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 969 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 9800 Page 16752 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Door Lock and Side Window Switch Replacement - Driver Side Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Page 4171 Customer TPMS Information Page 18787 Page 24386 Disclaimer Page 10753 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 6320 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 14783 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 10584 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 11686 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 11422 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 2861 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 5045 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12609 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 1682 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 5997 Page 15735 3. Install the negative battery cable clip (2) to the right wheelhouse liner. 4. Raise and support the vehicle. 5. Install the negative battery cable clip (1) to the chassis harness. 6. Route the negative battery cable terminal (3) through the opening between the radiator support and frame. 7. Ensure that the negative battery cable is positioned behind the forward lamp harness. 8. Install the forward lamp wiring harness terminal (2) to the frame. Ensure that the anti-rotation tab is inserted into the hole in the frame. 9. Install the forward lamp wiring harness ground bolt (1). Tighten the bolt to 25 N.m (18 lb ft). Page 6626 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 14350 Wheel Hub: Specifications Hub Nut ............................................................................................................................................... .................................................... 240 N.m (177 lb ft) Page 1951 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Campaign - Front And Rear Chrome Interior Door Handle Technical Service Bulletin # 09239A Date: 100825 Campaign - Front And Rear Chrome Interior Door Handle SPECIAL COVERAGE Bulletin No.: 09239A Date: August 25, 2010 Subject: 09239A - Special Coverage Adjustment - Front and Rear Chrome Interior Door Handle Lever Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL Equipped with Chrome Interior Door Handles Supercede: The Parts Information section has been revised to include a note that P/N 88880051 is used for the front and rear doors. Step 6 under the Rear Side Door Inside Handle Replacement procedure has also been revised to refer technicians to the Rear Side Door Inside Handle Replacement in SI.Please discard all copies of bulletin 09293, issued July 2010. Condition Some customers of 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles may comment about peeling on the top surface of the front or rear chrome interior door handle(s). A chrome plating irregularity combined with direct sunlight exposure may cause the plating to separate from the top surface of the handle on certain vehicles. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership or mileage. Dealers are to replace the front and/or rear chrome interior door handle levers if signs of peeling are present. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after July 16, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to July 16, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles built within the following VIN breakpoints: Trim Height Inspection Alignment: Service and Repair Trim Height Inspection Trim Height Inspection Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can the vehicle to cause bottom out over bumps, damage to the suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label. * Check the fuel level. Add additional weight if necessary to simulate a full tank of gas. (One U.S. gallon of gasoline weights approximate 6.5 lbs. One liter of gasoline weights 0.70 kg) * Make sure the passenger and rear compartments are empty, except for the spare tire. * Make sure the vehicle is on a level surface, such as an alignment rack. * For vehicles equipped with automatic level control, make sure that the system is functioning properly. * Make sure that all doors, lift gate/trunk and the hood are securely closed. * Check for installed after market accessories or modifications that could affect trim height measurements: - Larger or smaller than production wheels and tires - Lifting or lowering kits - Wheel opening flares - Ground affects * Remove the alignment rack floating pins. Measuring the Z Height Important: For vehicles equipped with torsion bars, the Z height must be verified before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use a adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. Important: All dimensions are measured vertical to ground. Cross vehicle Z heights should be within 12 mm (0.47 in) to be considered correct. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. Page 5989 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 10251 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 6366 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 20653 Note Using the punch and hammer, strike the rounded end of the roll pin to loosen the roll pin. The head of the roll pin should protrude from the handle housing. Remove the roll pin with pliers as shown in the illustration. 3. Using a punch, hammer, and pliers, remove the roll pin from the inside door handle. 4. Discard the roll pin. 5. Install the new roll pin that is included in the door handle kit, P/N 88880051. 6. Install the front side door inside handles. Refer to Front Side Door Inside Handle Replacement in SI. Rear Side Door Inside Handle Replacement 1. Remove the driver and passenger rear side door inside handles. Refer to Rear Side Door Inside Handle Replacement in SI. 2. Place rear side door inside handles on a work bench. Note Using a punch and hammer, strike the rounded end of the roll pin to loosen the roll pin. The head of the roll pin should protrude from the handle housing. Remove the roll pin with pliers as shown in the illustration. 3. Using a punch, hammer, and pliers, remove the roll pin from the inside door handle. 4. Discard the roll pin. Page 10625 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Steering/Suspension - Pitman Arm Shaft Seal Service Kit Steering Gear Seal: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1282 Page 14633 Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Notice: Refer to Fastener Notice. 3. Install the speed sensor bolt (1). Tighten bolt to 12 N.m (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Page 9167 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 18180 Wheel Fastener: Specifications Wheel Nuts Tighten the nuts evenly and alternately in order to avoid excessive runout. Tighten the wheel nuts as shown to .................................................................................................................................................... 190 N.m (140 lb ft). Page 22554 Seat Latch: Service and Repair Rear Seat Latch Replacement (Crew Cab with A68) Rear Seat Latch Replacement (Crew Cab with A68) Page 7817 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 15867 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6168 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 9775 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 18720 If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Director, Customer and Relationship Services Page 16936 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 6767 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 18901 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5959 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 16683 Page 19868 Method 1 Method 2 Page 509 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 6154 Page 6300 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 21585 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 3106 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 1530 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (JD9, JF3, JF7) Page 22454 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 7213 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 3270 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.3L) Removal Procedure 1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Page 12522 Vehicle Zoning Strategy Truck Zoning Page 8114 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 7465 Disclaimer Page 15912 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 16982 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 7854 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 6103 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12518 Page 8897 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 609 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 17384 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Page 19813 Page 19377 Object Sensor - Right Rear Corner Object Sensor - Right Rear Middle Procedures Steering Angle Sensor: Procedures Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 23125 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 18073 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 11160 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 14154 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Notice: Refer to Fastener Notice. 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 9. Lower the vehicle. Page 6789 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 10281 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 16460 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) (U42) Page 13688 1. Install the transmission range selector cable bracket. Notice: Refer to Fastener Notice. 2. Install the transmission range selector cable bracket bolts (1). Tighten the bolts to 25 N.m (18 lb ft). 3. Align and install the cable to the bracket. 4. Install the retainer that secures the cable to the bracket. 5. Lower the vehicle. 6. Check the vehicle for proper operation. If cable adjustment is necessary, refer to Range Selector Lever Cable Adjustment. Page 12998 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 24547 11. Connect the large two-wire connector (1) to the body harness (2). 12. Connect the small five-wire connector (1) to the body harness (2). 13. Secure the large two-wire connector and small five-wire connector to the windshield washer solvent heater assembly bracket. 14. Connect the two windshield wiper solvent inlet and outlet hoses together. Use a portion of the rubber wiper solvent hose removed in Step 1 if needed to join the two plastic wiper solvent hoses together. Discard the remaining portions of the rubber windshield wiper solvent hoses. 15. Route and secure windshield wiper solvent hose along passenger side front fender. Page 13746 Page 1683 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 14056 3 - Exhaust Pressure Regulator Valve Spring 4 - Exhaust Pressure Regulator Valve 5 - Retaining Clip 6 - Control Relief Spring 7 - Control Relief Valve 8 - Main Valve Body 9 - Locating Pin (4) 10 - Locating Pin 11 - Pressure Control Solenoid 1 (PCS1) Spring 12 - PCS1 Valve 13 - PCS1 Spring 14 - Trim Gain Valve 15 - PCS1 16 - PCS1 O-Ring 17 - PCS2 Spring 18 - PCS2 Valve 19 - Trim Gain Valve 20 - PCS2 21 - PCS2 O-Ring 22 - Shift Solenoid (SS) 3 23 - SS3 O-Ring 24 - SS3 O-Ring 25 - SS2 26 - SS2 O-Ring 27 - SS2 O-Ring 28 - Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Spring 29 - TCC PCS Valve 31 - TCC PCS 32 - TCC PCS O-Ring 33 - TCC PCS O-Ring 34 - TCC PCS Retaining Bracket 35 - SS2 and SS3 Retainers (2) 36 - Accumulator Plug (2) 37 - Accumulator Spring (2) 38 - PCS1 and PCS2 Retaining Bracket Page 7959 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 2888 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 11437 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 17319 Multiple Junction Connector: Diagrams X300 - X399 X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Harness (Gas) X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 6543 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 24271 1 - Window Switch - Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 3 - Door Latch Assembly - Right Rear 4 - Speaker - Right Rear Door 5 - Window Motor Right Rear (A31) Left Rear Door (Extended Cab) Page 22991 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 15634 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 9663 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 14462 Universal Joint: Service and Repair Universal Joint Replacement - External Snap Ring Universal Joint Replacement - External Snap Ring Tools Required * J 9522-3 U-Joint Bearing Separator * J 9522-5 U-Joint Bearing Spacer Remover Disassembly Procedure Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal. 1. Support the propeller shaft in a line horizontal with the table of a press. 2. Mark the propeller shaft in order to show which end connects to the transmission and which end goes to the rear axle. 3. Disassemble the snap rings by pinching the ends together with a pair of pliers. 4. If the ring does not readily snap out of the groove in the yoke, tap the end of the cup lightly in order to relieve the pressure from the ring. 5. Place the universal joint so that the lower ear of the yoke is supported on a 30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket. 6. Place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup out of the yoke ear. 7. If you do not completely remove the bearing cup, lift the cross and insert J 9522-5 between the seal and the bearing cup you are removing. Continue pressing the bearing cup out of the yoke. 8. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke. 9. Mark the orientation of the slip yoke to the tube for proper reassembly. 10. Remove the cross from the yoke. 11. Remove the remaining universal joint parts from the yoke. 12. If you are replacing the front universal joint, remove the bearing cups in the slip yoke in the same manner. 13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring. 14. Inspect the bearing cup bores for burrs or imperfections. 15. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old retaining ring may prevent the bearing cups from pressing into place or prevent the bearing retainers from properly seating. Assembly Procedure 1. Remove the bearing cups from the universal joint. Page 11602 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 18152 Page 10371 Fuel Injector: Locations Engine Controls Component Views Rear of the Engine 1 - Central Sequential Fuel Injection (SFI) Module 2 - Manifold Absolute Pressure (MAP) Sensor 3 G106 4 - Engine Oil Pressure (EOP) Sensor 5 - Ignition Control Module (ICM) 6 - G107 Page 22645 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 22191 Page 9055 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 15344 Page 8751 Body Control Module (BCM) X4 Page 6483 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 3390 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Page 3123 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. HVAC - Automatic Low Pressure Sensor / Switch: Locations HVAC - Automatic HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 17171 Page 11609 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 16021 Junction Block - Left I/P, Label Electrical Center Identification Views Junction Block - Left I/P, Label Page 9507 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 5190 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 23873 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6117 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 12717 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 14808 Shift Solenoid: Connector Views 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Page 6047 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 3527 4. Loosen the air cleaner housing screws. 5. Lift up the air cleaner housing cover. 6. Remove the air filter element. Installation Procedure 1. Insert the NEW air filter element. 2. Install the air cleaner housing cover. Notice: Refer to Fastener Notice. 3. Tighten the air cleaner housing screws. Tighten the screws to 3 N.m (27 lb in). Page 20725 Page 2918 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 344 Sunroof / Moonroof Module: Diagrams Sunroof Connector End Views Sunroof Module Page 2977 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 695 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 24726 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 17848 Page 8885 Page 24497 Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within Page 9187 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10277 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Shift Solenoid Valve State and Gear Ratio Page 12528 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 3606 Step 8 - Step 16 Page 5773 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 21978 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Crew Cab New Motor) Initialization/Teach Procedure (Manual Method), New/First Time Installation Perform the initialization/teach procedure at the first operation test of the sunroof. Ensure the electrical harness on the headliner is connected to the large roof, battery power is applied and the ignition switch is on. 1. Press the sunroof switch to the VENT OPEN position until the window stall at the front hard stop in the VENT OPEN position, and then moves slightly to the soft stop position. Release the button. (This is the initialization portion). 2. Within 3 seconds, press and hold the sunroof switch-vent open again. The sunroof window will move toward and past the flush position. (This is the teach portion). 3. Continue holding the switch until the sunroof window moves to full open and then back to close and stops at the closed position. Release the button. The initialization/teach procedure is complete. 4. Verify the operation of the roof. The initialization/teach procedure is not completed if one of the following events occurs before the initialization/teach cycle is finished: * The sunroof switch is not held in the VENT OPEN position. * Ignition and/or battery power has been removed. * Glass panel has not reached the CLOSE position. If the initialization/teach procedure is not carried out completely, it must be started again. Page 11568 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 11360 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 11343 Page 8955 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 15171 Wheel Speed Sensor (WSS) - Right Front (JH6/JH7) Wheel Speed Sensor (WSS) - Right Rear (JL4) Wheel Speed Sensor (WSS) - Right Rear (JL4) Wheel Speed Sensor (WSS) - Right Rear (JL4) Page 17501 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 17678 Pitman Arm: Service and Repair Pitman Arm Replacement Tools Required * J 6632-01 Pitman Arm Puller * J 29107-A Pitman Arm Puller Removal Procedure 1. Remove the steering gear. 2. Place the steering gear into a vise. 3. Remove the pitman arm nut (1) and washer (2). 4. Remove the pitman arm from the pitman arm shaft using puller J 6632-01 or puller J 29107-A. Installation Procedure 1. Install the pitman arm onto the steering gear. Page 17950 Page 14565 Fluid Pressure Sensor/Switch: Diagrams Automatic Transmission Internal Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Page 306 Power Seat Control Module: Service and Repair Memory Seat Control Module Replacement Page 24338 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 317 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 20068 Central Control Module: Diagrams Entertainment/Communication Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Page 11025 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 484 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Page 11486 5. Install the appropriate spark plug wire boot(s) (1, 2) to the ignition coil. 6. Inspect the spark plug wires for proper routing (1, 2, 3, 4, 5, 6) and installation. 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 3. Any time the spark plug wire or boot are installed on the spark plug, new dielectric grease needs to be applied inside the boot. Page 2277 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 7844 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 1369 Power Door Lock Switch: Diagrams Vehicle Access Connector End Views Door Lock Switch - Driver (AU3 -AN3/DL3) Door Lock Switch - Passenger (AU3 -AN3/DL3) Page 15941 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 10749 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 8642 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1) from the HO2S pigtail electrical connector. 4. Remove the HO2S pigtail electrical connector clip (2) from the frame. 5. Remove the HO2S (4). Page 15887 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 24663 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 10097 21. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 N.m (18 lb ft). 22. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. 23. Lower the vehicle. 24. Remove the caps from the fuel rail and EVAP line. 25. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. 26. Connect the fuel feed line (1) quick connect fitting to the fuel rail. 27. Install the fuel fill cap. 28. Connect the negative battery cable. 29. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Page 12903 Page 20043 Speaker - Right Rear (Regular Cab) A/T Shift Lock Control Solenoid Speaker - Right Rear Door (Extended Cab/Crew Cab +UQ3/UQ5) A/T Shift Lock Control Solenoid A/C - Does Not Cool/Can't Change Mode/DTC's Set Multiple Junction Connector: All Technical Service Bulletins A/C - Does Not Cool/Can't Change Mode/DTC's Set Bulletin No.: 07-01-38-009B Date: November 28, 2007 TECHNICAL Subject: EI07264 - Manual HVAC, Temperature or Mode Actuator Performance, A/C Does Not Cool, Unable to Change Mode, DTC B0228, B0413, B0423, B0433, B3779, B3782 (Diagnose for Intermittent Wiring Connection at RH BEC) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Extended and Crew Cab Models Only with Manual Temperature Control HVAC System (RPO C67) Supercede: This bulletin is being revised to end the need for engineering information and to provide diagnostic procedures to accurately diagnose this condition. Please discard Corporate Bulletin Number 07-01-38-009A (Section 01 - HVAC). Condition This concern only applies to Extended or Crew cab vehicles. If the customer did not bring their vehicle in for this concern, do no proceed with this bulletin. Some customers may comment that the A/C blows hot air or is inoperative. They may also comment that they are unable to change the temperature or HVAC mode of the vehicle. Under these conditions, the actuator has moved to a default position. Refer to the table. Cause Page 15253 WARRANTY INFORMATION Page 12917 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or greater. 6. Remove the TCC PCS retaining bolt and retaining bracket. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Page 20931 Rear Door Hinge: Service and Repair Rear Side Door Hinge Replacement (Crew Cab) Rear Side Door Hinge Replacement (Crew Cab) Page 14745 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 12536 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 9467 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 16500 Page 9851 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 13156 Page 9443 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 17576 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Page 11591 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 24546 6. Cut the five-wire connector from the windshield washer solvent heater assembly. Vary the length of the five wires on the connector. 7. Discard the windshield washer solvent heater assembly and, if install in recall 08048, the jumper harness with inline fuse. 8. Wrap the large connector with two wires in electrical tape. 9. Wrap the red and green wires on the small connector separately. 10. Wrap the five wires on the small connector with electrical tape. Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 9520 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 3964 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6894 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11493 14. If required, remove the ignition coil bracket bolts and bracket. Installation Procedure Notice: Refer to Fastener Notice. 1. If required, position the ignition coil bracket to the lower intake manifold and install the bolts. Tighten the bolts to 12 N.m (106 lb in). Page 16438 Multiple Junction Connector: Diagrams X400 - X499 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X414 Inline Harness Connector End Views X414 Chassis Harness to Camper Harness (UY2/8S3) Procedures Throttle Body: Procedures Throttle Body Cleaning 1. Remove the air cleaner outlet duct. Caution: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. Notice: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. 2. Inspect the throttle body bore and throttle plate for deposits. You need to open the throttle plate in order to inspect all surfaces. Notice: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 (Canadian P/N 993026), or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product. 4. Install the air cleaner outlet duct. Page 2947 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 1764 Accelerator Pedal Position Sensor: Diagrams Engine Controls Connector End Views Accelerator Pedal Position (APP) Sensor Page 2680 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Audio System - Static/Ignition Noise on AM Band Ground Strap: Customer Interest Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Page 17528 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: All Technical Service Bulletins Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Page 2684 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 7892 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Controls Connector End Views Engine Coolant Temperature (ECT) Sensor Page 3979 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 14347 Page 7165 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 12230 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 20694 The latch and its backing plate have been removed on the above illustration to show the location for the lube. 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 05-08-64-002B Date: 060403 Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Page 24102 Disclaimer Page 15385 Brake Hose/Line: Service and Repair Front Brake Hose Replacement (JH6, JH7) Front Brake Hose Replacement (JH6, JH7) Page 570 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 10832 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 11315 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 24166 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 24200 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 16904 Vehicle Zoning Strategy Truck Zoning Page 13002 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 12987 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 07-08-44-013A - END OF NEED FOR INFORMATION Speaker: All Technical Service Bulletins 07-08-44-013A - END OF NEED FOR INFORMATION ENGINEERING INFORMATION Bulletin No.: 07-08-44-013A Date: July 16, 2009 Subject: EI07199 - Radio Speaker Buzz Noise (Engineering Information Closed) Models: 2007 Chevrolet Silverado 2007 GMC Sierra Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 07-08-44-013 (Section 08 - Body and Accessories). GM Engineering investigated vehicles with your assistance in the field, but did not identify a single point issue (root cause) for this condition. Due to this cooperation, engineering is satisfied with the data collected and requires no further response. Please refer to SI and use the established diagnostic information to correct the customer concern. Disclaimer Page 14390 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14703 Page 17083 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3669 Notice: Refer to Fastener Notice. 5. Install the oil pan bolts. Tighten the bolts alternately and evenly to 11 N.m (97 lb in). 6. Install the catalytic converter. 7. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 N.m (18 lb ft). 8. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 6485 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 7918 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 11247 Page 6933 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15284 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Measurement 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction. See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Correction Page 9325 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 14835 Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 1154 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Engine Controls - Cruise Control Turns Off When Operated Cruise Control: All Technical Service Bulletins Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1869 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 8968 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 3064 Page 24718 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 20345 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 19714 Page 23611 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 9073 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 11540 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 1153 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: All Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Page 16391 X110 Inline Harness Connector End Views X110 Engine Harness (-Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF/NQG/NQH/NP2) Page 11821 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 12825 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 6563 1. Install a NEW MAP sensor seal to the MAP sensor, if necessary. 2. Install the MAP sensor (2) to the upper intake manifold. Notice: Refer to Fastener Notice. 3. Install the MAP sensor bolt (1). Tighten the bolt to 10 N.m (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the MAP sensor. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 21375 Page 9588 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6347 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 6341 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 23537 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) X3 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) X4 Page 13548 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 15671 Steering Angle Sensor: Diagrams Steering Angle Sensor (JL4) Steering Wheel Speed/Position Sensor Steering Angle Sensor (JL4) Page 2370 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Lighting - Dome/Reading Lamps Inoperative Map Lamp: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 8619 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 2210 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 13535 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 3723 Important: The power steering gear inlet hose cannot be routed between the brake lines and the power brake booster during installation. 1. Route the power steering gear inlet hose in the same position it was in prior to removal. 2. Install the power steering gear inlet hose (2) to the power brake booster (1) and hand tighten only. Rotate the power steering gear inlet hose clockwise until the it contacts the power brake booster housing and then hold it in position while tightening it to the fitting specification. Notice: Refer to Fastener Notice. 3. Install the power steering gear inlet hose (2) to the power steering gear. Tighten the fittings to 32 N.m (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Page 4162 Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Page 6621 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Capacity Specifications Fluid - Differential: Capacity Specifications AXLE CAPACITIES FRONT AXLE 1000 Series (8.25") ...................................................................................................... ..................................................................... 1.43 liters (1.51 quarts) 2000 Series (9.25") .................. ......................................................................................................................................................... 1.73 liters (1.83 quarts) REAR AXLE 1000 Series With RPO AXN (9.5" LD) ........................................................................... ...................................................................................... 2.6 liters (2.75 quarts) Without RPO AXN (8.6") .................................................................................................................................................... ............. 2.03 liters (2.15 quarts) 2000 Series (9.5" HD) ..................................................................... ................................................................................................... 2.6 liters (2.75 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 2770 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 8135 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 18915 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular Cab +10 Series +ASF) Keyless Entry Antenna Replacement (Regular Cab) Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Regular Cab) Keyless Entry Antenna Replacement (Regular Cab) Page 23067 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 13763 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 15640 Trailer Brake Control Module: Service and Repair Trailer Brake Control Relay Replacement Trailer Brake Control Relay Replacement Page 8532 Oxygen Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 6059 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 2699 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 23021 Cruise Control: Symptom Related Diagnostic Procedures Symptoms - Cruise Control Symptoms - Cruise Control Important: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data link. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Cruise Control Description and Operation. Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the Cruise Control System. * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in Diagnostic Aids. See: Testing and Inspection/Component Tests and General Diagnostics Symptom List Refer to Cruise Control Inoperative/Malfunctioning. Cruise Control Inoperative/Malfunctioning Cruise Control Inoperative/Malfunctioning Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provides an overview of each diagnostic category. Circuit/System Description The cruise control switch is an input to the body control module (BCM). The BCM monitors the cruise control on/off, set/coast, resume/accelerate, and cancel switch signal circuits in order to detect when a cruise control function switch has been activated. The BCM detects a predetermined voltage signal when a cruise control function switch is applied, with each switch having a different voltage value. Conditions for Enabling Cruise Control * The vehicle speed is greater than 40 km/h (25 mph). * The vehicle is not in PARK, REVERSE, NEUTRAL, or 1st gear. * The system voltage is within 9-16 volts. * The park brake or brakes is not applied. Diagnostic Aids Important: Repair any brake system related symptoms and DTCs before performing this diagnostic. In order to avoid misdiagnosis, inspect for the following: * Ensure that the following cruise control switches are not stuck in the engaged position: - On/Off switch - - SET switch Page 3163 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 436 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 24331 For vehicles repaired under warranty, use the table. Disclaimer Page 14463 2. Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear toward the bottom. 3. Assemble the cross into the yoke so that the trunnion seats freely into the bearing cup. 4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 5. Install the opposite bearing cup part way into the yoke ear. 6. Ensure that the trunnions start straight and true into both bearing cups. 7. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang up or binding, stop pressing. Inspect the needle bearings for misalignment in the bearing cup. 8. Press the bearing cup into the yoke until the bearing cup retainer groove is visible over the top of the bearing cup. 9. Assemble the bearing retainer in the retainer groove. 10. Continue pressing until both retainers can be snapped into place. Page 10419 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 14771 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 13549 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11393 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 11660 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 11670 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 12276 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 22477 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 4095 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 10296 Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provides an overview of each diagnostic category. Test Description Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent in nonblended gasoline, or greater than 85 percent with E85 blended gasoline for flexible fuel applications, can cause driveability conditions such as hesitation, lack of power, stalling, or a no start, and may contribute to fuel system corrosion, deterioration of fuel system components, and a restricted fuel filter. System Verification The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, perform the Particulate Contaminants in Fuel Testing Procedure. If alcohol contamination is suspected, perform the Alcohol in Fuel Testing procedure. Alcohol in Fuel Testing with Special Tool 1. Test the fuel composition using J 44175 and Instruction Manual. 2. If water appears in the fuel sample, clean the fuel system. 3. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. 4. If the nonblended gasoline fuel sample measures more than 15 percent ethanol, or if the E85 blended gasoline fuel sample measures more than 91 percent ethanol, add fresh regular gasoline to the vehicles's fuel tank. 5. Test the fuel composition. 6. If additional testing indicates that the ethanol percentage is still above 15 percent for a nonblended gasoline sample, drain and replace the vehicle's fuel. Refer to Fuel Tank Draining. If additional testing indicates that the E85 blended gasoline sample still measures above 91 percent, continue adding fresh, regular gasoline until the ethanol content is 85 percent or less. Alcohol in Fuel Testing without Special Tool 1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.38 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants in Fuel Testing Procedure 1. Using an approved fuel container, draw approximately 0.5 liter (0.53 qt) of fuel. 2. Place the container on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. 3. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel system. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Computers and Control Systems/Testing and Page 3080 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 3913 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 10736 Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 18727 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2816 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 5381 Page 10213 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 188 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 6785 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 16398 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6) A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 6975 Page 18263 Disclaimer Page 18854 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Page 10230 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10185 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 7269 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 13095 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 22935 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 7980 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 18208 Page 3779 Fluid - Differential: Fluid Type Specifications FRONT AXLE (1500 SERIES) SAE 80W-90 Axle Lubricant (GM Part No. U.S. 89021671, in Canada 89021672). FRONT AXLE (1500 HD, 2500, 2500 HD, AND 3500 SERIES) SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. REAR AXLE SAE 75W-90 Synthetic Axle Lubricant (GM Part No. U.S. 89021677, in Canada 89021678) meeting GM Specification 9986115. Page 536 Front Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Front Seat Adjuster Switch Knob Replacement Front Seat Adjuster Switch Knob Replacement Page 12837 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 22502 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 2614 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 23086 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 6041 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Locations Crankshaft Position Sensor: Locations Engine Controls Component Views Right Side of Engine 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 11466 Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face the engine front cover. Failure to do so will damage the front cover and the reluctor ring. 1. Install the CKP sensor reluctor ring. 1. Align the keyway on the CKP sensor reluctor ring with the key in the crankshaft. 2. Using J 5590, push the CKP sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. 2. Install the engine front cover. Procedures Brake Drum: Procedures Brake Drum Refinishing Tools Required j 41013 Rotor Resurfacing Kit Important: DO NOT refinish the brake drums in order to correct any of the following complaints: * Brake noise (growl/squeal) * Premature brake lining wear * Cosmetic or superficial corrosion of the drum braking surface * Drum discoloration Refinish the brake drums ONLY when 1 or more of the following conditions exist: * Severe scoring of the drum braking surface (groove depth in excess of specification) * Brake pulsation caused by the following: - Brake drum out of round (runout in excess of specification) - Corrosion or pitting that is deeper than the drum braking surface 1. Use a micrometer in order to measure the largest diameter of the brake drum. If the largest diameter of the brake drum exceeds the brake drum maximum refinish diameter, DO NOT refinish the brake drum. Replace the brake drum. 2. Use the J 41013 or an equivalent tool in order to THOROUGHLY clean the rust from the brake drum flange. 3. Refinish the brake drum. Refer to the brake lathe manufacturer's operating instructions. Important: Failure to obtain the best possible braking surface finish may cause the vehicle to stop with difficulty. 4. After machining the brake drum, use 120 grit aluminum oxide sandpaper in order to create a non-directional braking surface. 5. Clean the braking surfaces with GM P/N 12377981 (Canadian P/N 10953463) or equivalent brake parts cleaner. Page 9843 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 9081 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 12961 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 5389 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 7814 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 24715 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 521 Page 14228 12. Inspect and add axle lubricant to the axle housing, if necessary. 13. Lower the vehicle. Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement Tools Required * J 44414 Pinion Seal Installer * J 22912-B Bearing Puller * J 24433 Pinion Cone and Side Bearing Installer * J 37624 Pinion Bearing Installer * J 8092 Driver Handle * J 8608 Rear Pinion Bearing Race Installer * J 8614-01 Flange/Pulley Holding Tool Removal Procedure Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the axle lubricant. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 3. Remove the axle shafts. 4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 5. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 6. Measure the amount of torque required to rotate the pinion and the ring gear. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion pilot bearing Front Wheel Speed Sensor Replacement (JD9, JF3, JF7) Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement (JD9, JF3, JF7) Front Wheel Speed Sensor Replacement (JD9, JF3, JF7) Page 8747 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module 7 - Fuse Block - I/P Page 6746 View of the connector when released from the component. View of another type of Micro 64 connector. Page 18257 Disclaimer Page 5278 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 14927 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 19170 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 9881 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 17599 1. Loosen the jam nut on the inner tie rod (1). 2. Rotate the inner tie rod (2) to the required toe specification setting. Refer to Wheel Alignment Specifications. Notice: Refer to Fastener Notice. 3. Tighten the jam nut (1) on the tie rod. Tighten the tie rod jam to 75 N.m (55 lb ft). 4. Check the toe setting after tightening. 5. Re-adjust the toe setting if necessary. Page 21695 Passenger Door Switch (PDS) X1 (AN3/DL3) Passenger Door Switch (PDS) X2 (AN3/DL3) Page 2635 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 7216 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 3090 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 7924 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 5864 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Door Lock and Side Window Switch Replacement - Driver Side Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Page 1032 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 7610 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 207 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 7085 Camshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 10867 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 9532 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 3129 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 23609 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 15353 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Page 6556 5. Remove the knock sensor bolt and sensor. Installation Procedure Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). Page 9629 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 2501 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 23567 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 4580 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Removal Procedure 1. Remove the drive belt. 2. Remove the belt tensioner bolt. 3. Remove the belt tensioner. Ensure that there is a locating pin (1) on the tensioner. Installation Procedure 1. Install the belt tensioner. Position the locating pin (1) on the tensioner into the hole in the generator bracket. Notice: Refer to Fastener Notice. 2. Install the belt tensioner bolt. Tighten the bolt to 50 N.m (37 lb ft). 3. Install the drive belt. Page 20539 Page 11726 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 22709 Splash Guard: Service and Repair Engine Splash Shield Replacement - Right Side Engine Splash Shield Replacement - Right Side Page 22837 Front Door Weatherstrip: Service and Repair Front Side Door Roof Drip Weatherstrip Replacement Front Side Door Roof Drip Weatherstrip Replacement Page 16344 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 20487 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 18932 Disclaimer Page 7659 Battery Current Sensor: Diagrams Battery Current Sensor (10 Series) Battery Current Sensor (10 Series) Page 19395 The DIC displays the timer in the following format: XX: XX:XX: The first XX represents hours elapsed, the second XX represents minutes elapsed, and the third XX represents seconds elapsed. The maximum range of the timer is 99 hours, 59 minutes, and 59 seconds. After the maximum range is reached, the timer displays all zeros (00:00:00). Park Assist Menu The park assist menu is displayed in the DIC. The DIC displays the current state of the park assist until the IPC receives a message indicating otherwise. The DIC displays (- - -) when communication with park assist is lost. English/Metric The English/Metric mode is used to toggle between English and Metric units and can be accessed through the driver information center (DIC) Vehicle Info switch. Trip A/B The trip odometer A or B can be accessed through the DIC Trip/Fuel switch function. Language The driver information center (DIC) is capable of displaying in 8 languages * English * German * Italian * French * Spanish * Arabic * Chinese * Korean Page 7215 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Campaign - BCM Reprogramming for Battery Drain Body Control Module: Recalls Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 7051 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 15168 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Page 17382 X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) X321 Page 20767 Front Door Weatherstrip: Service and Repair Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Side Door Bottom Auxiliary Sealing Strip Replacement Page 15224 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered, non-lubricated compressed air. Assembly Procedure Important: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure that the square-cut piston seal is not twisted. Page 12291 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control Solenoid 1 (PCS1) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Page 13847 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 13459 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 12692 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 2094 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Rear Side Door Outside Handle Replacement (Crew Cab) Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement (Crew Cab) Rear Side Door Outside Handle Replacement (Crew Cab) Page 11322 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 24278 Page 5315 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 3069 Page 10497 Tighten the nuts to 3 N.m (27 lb ft). 51. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent, to the threads of the fuel feed pipe bracket stud (3). 52. Install the fuel feed pipe bracket stud (3). Tighten the stud to 6 N.m (53 lb ft). 53. Install the brake booster vacuum hose and connector to the intake manifold. 54. Install the resonator and air inlet duct to the throttle body. 55. Install the PCV clean air tube to the inlet duct. 56. Install brake booster vacuum hose and connector to the intake manifold. 57. Install ignition wires 1, 3, and 5 to the distributor cap. 58. Add 1 ounce of port fuel injector cleaner GM P/N 12345104 (Canadian P/N 12345515), or equivalent to the vehicle fuel tank for each gallon of gasoline estimated to be in the tank. Important: Instruct the customer to add the remainder of the bottle of port fuel injector cleaner to the vehicle fuel tank at the next fill up. 59. Hand tighten the fuel tank filler cap. 60. Start the vehicle and check for fuel leaks. 61. Using a Tech II scan tool, check for any stored Powertrain DTC codes. Clear codes as required. 62. Disconnect Tech II scan tool. Page 8019 Campaign - BCM Reprogramming for Battery Drain Body Control Module: Recalls Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 12542 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 10479 Page 5880 3. Position the engine wiring harness lower electrical connector and engage the retainer (3) securing the lower connector (4) to the ECM. 4. Position the engine wiring harness upper electrical connector and engage the retainer (2) securing the upper connector (1) to the ECM. 5. Connect the negative battery cable. 6. If a NEW ECM was installed, program the ECM. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 5700 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 17045 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 13718 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 7839 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 21509 Page 8830 Page 10286 Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Page 7292 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 12250 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 16537 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 12325 Control Module: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Control Module Replacement Page 1548 Steering Angle Sensor: Diagrams Steering Angle Sensor (JL4) Steering Wheel Speed/Position Sensor Steering Angle Sensor (JL4) Page 2395 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 1160 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 21423 The four outer tabs will not allow the cup liner to seat properly into the rear cupholder assembly causing a poor fit and a gap. Carefully cut off the two front outer tabs (1), referring to the graphic above, and cut off the two back outer tabs. Install the updated rear console cup liner as shown above. Close the console cupholder assembly. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16308 Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Page 24712 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 11723 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 16784 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Electrical - No Start/No Crank/Int Electrical Operations Multiple Junction Connector: All Technical Service Bulletins Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Evaporative Emission (EVAP) Hoses/Pipes Replacement Engine Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine Evaporative Emission Hoses/Pipes Replacement - Engine Removal Procedure Important: Clean the evaporative emission (EVAP) line connection and surrounding areas before disconnecting in order to avoid possible EVAP system contamination. 1. Disconnect the EVAP canister purge solenoid valve tube quick connect fitting (2) from the chassis EVAP line. 2. Disconnect the EVAP canister purge solenoid valve tube quick connect fitting (1) from the EVAP canister purge solenoid valve. 3. Remove the EVAP canister purge solenoid valve tube. 4. Cap the EVAP canister purge solenoid valve and the chassis EVAP pipe in order to prevent possible EVAP system contamination. Page 17154 Part 2 Electrical Center Identification Views Junction Block - Right I/P, Top View Junction Block - Right I/P (Wire Entry) Page 7893 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor from the cylinder head. Installation Procedure Notice: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, Page 6026 Page 23649 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Fuse Block - I/P, Top View Fuse: Application and ID Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Label Page 10038 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 6804 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 17775 Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Page 20673 Driver/Vehicle Information Display: Service and Repair Driver Information Display Switch Replacement (with RPO SLT) Driver Information Display Switch Replacement (with RPO SLT) Page 24337 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 17132 Fuse Block: Connector Views Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Top View Fuse Block - I/P, Bottom View Page 15744 5. Remove the auxiliary battery positive cable connector (1) from the underhood bussed electrical center (UBEC). 6. Remove the mega fuse cover (3). 7. Disconnect the auxiliary battery positive cable electrical connector (2) from the engine wiring harness connector. 8. Remove the relay (1) clip from the stud on the front of dash. Page 6016 Accelerator Pedal Position Sensor: Diagrams Engine Controls Connector End Views Accelerator Pedal Position (APP) Sensor Page 1835 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 24149 Page 11048 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 14372 6. Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 7. Road test the vehicle and verify that the noise is gone. Note Do Not replace the slip yoke unless the cleaning and lubrication procedure is ineffective. 8. If the vehicle has a repeat concern after lubricating the slip yoke splines, it may be necessary to replace the propeller shaft slip yoke with a new nickel-plated slip yoke. Replace the Propeller Shaft Slip Yoke 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. Important Some U-joints are fastened with nylon injection clips. If so, Do Not reuse the U-joint. Replace with GM P/N 12479126 U-Joint kit. 2. Replace the propeller shaft slip yoke with a new nickel-plated slip yoke. Refer to Propeller Shaft Slip Yoke Replacement in SI. 3. Install the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Specifications Compressor Clutch: Specifications Clutch Gap............................................................................................................................................ ...................................0.35-0.65 mm (0.014-0.026 in) Page 9633 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 4696 6. Disconnect the following electrical connectors: * The evaporative emission (EVAP) canister purge solenoid valve (1) * The manifold absolute pressure (MAP) sensor 7. Disconnect the evaporative emission (EVAP) canister purge solenoid valve tube quick connect fitting (1) from the EVAP purge solenoid valve. 8. Reposition the tube out of the way. Page 3907 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 3923 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 22304 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Page 5188 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 7611 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 22437 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 12169 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (367A) and the 1-2 shift solenoid retainer (395). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. 4. Install the pressure control solenoid (377). Notice: Refer to Fastener Notice. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Page 21904 Memory Seat Module X3 (AN3) Page 16318 For vehicles repaired under warranty, use the table. Disclaimer Page 10964 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 10666 12. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 13. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line. 14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 15. Install the fuel line clip (1) to the bracket on the automatic transmission. Page 19802 8. The navigation radio automatically ejects the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 9. Load the update disc into the slot located behind the display screen by inserting it partially until the system pulls it in. 10. The screen "PREPARING TO LOAD SYSTEM SOFTWARE" will be displayed while the update is loading. The update should take approximately 4 minutes. 11. After the system restarts, press the "EJECT" soft key to eject and remove the software update disc. Important Dealers should retain the software update disc for their use. 12. Load the map DVD into the same slot located behind the display screen, DO NOT put in the top slot. 13. Press the "CLOSE" soft key. 14. Press the "OK" soft key. 15. Press the "MENU" hard key. Important The clock will not be displayed until it is confirmed by completing step 16. 16. Turn the engine OFF. Open and close the driver's door. Wait for 10 minutes. Important Due to the load time of the system, there may be a short delay before the "Map Screen" appears. 17. Restart the engine. After the map screen is displayed, verify that the clock is visible and touch the map screen to confirm that it can be scrolled. If the clock does not appear, repeat programming. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 18. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 19. Verify that the destination search area is properly displayed. 1. Press the "DESTINATION" hard key. 2. Press "CHANGE SEARCH AREA" soft key. 3. Select the correct area for the vehicle's location. Warranty Information Page 1911 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 20161 For vehicles repaired under warranty, use the table. Disclaimer Page 8927 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 2797 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 431 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 21408 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Page 22421 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 189 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 12275 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 13918 Transmission Position Switch/Sensor: Service and Repair Allison - Automatic Transmission Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 22455 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Campaign - Roof Lighting Circuit Addition Marker Lamp: Recalls Campaign - Roof Lighting Circuit Addition Subject: Service Update for Inventory and Customer Vehicles-Missing Circuit for Optional Roof Mounted Light (Beacon)-Expires with Base Warranty # 07029 - (01/29/2007) Models: 2007 Chevrolet Silverado 1500 2007 GMC Sierra 1500 with Optional Roof Mounted Light (TRW & -YE9) THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN FOR ANY TYPE OF SERVICE AND WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to create a circuit for the optional roof mounted light on certain 2007 Chevrolet Silverado 1500 and GMC Sierra 1500 vehicles equipped with provisions for an optional roof mounted light (TRW & -YE9). On these vehicles, the circuit for the operation roof mounted light is missing. This service procedure should he completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Parts Information Parts required to complete this service update are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Tools Required J 38125 Terminal Repair Kit Page 12444 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 3076 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Electrical - Various Rear Door Electrical Malfunctions Speaker: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 22000 Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement (Extended Cab) Sunroof Air Deflector Replacement (Extended Cab) Removal Procedure 1. Open the power sunroof window to the fully rear position. 2. Remove the actuators screws (1) and actuators (2) from each side of the sunroof module. 3. Remove the screws (1) attaching the sunroof air deflector (2) to the sunroof module (3). 4. Slide the air deflector rearward until it releases from the sunroof module. 5. Remove the sunroof air deflector (2) from the sunroof module (3). Installation Procedure Page 6134 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 7378 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 15633 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 182 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 3709 2. Install the evaporator tube nut to the condenser. Tighten the nut to 16 N.m (12 lb ft). 3. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers, if equipped. 4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped. Tighten the nut to 16 N.m (12 lb ft). 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator. Tighten the nut to 16 N.m (12 lb ft). 7. Install the surge tank hold down nut and bolt and position aside. 8. Install the air cleaner assembly. 9. Install the upper radiator air baffle and deflector. 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the components using the J 39400-A. Page 6741 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 23601 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 2343 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 12376 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement. Page 19600 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Replacement Page 8261 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 12701 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 20830 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 15468 9. Remove the park brake cable assembly from the vehicle. Installation Procedure 1. Install the park brake cable assembly into the backing plate. 2. Install the brake shoes. 3. Install the park brake cable to the cable guides. Page 9654 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 17739 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Page 2725 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 265 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 3615 5. If equipped without A/C, install the belt (1) to the pulleys and the drive belt tensioner. 6. Slowly release the tension on the belt tensioner (2). 7. Remove the breaker bar from the drive belt tensioner. 8. Inspect the drive belt for proper installation and alignment. Page 8425 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 16928 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 22695 4. If a void is found (1), fill it with seam sealer Kent Automotive High-Tech(TM) Clear Sealer, P/N P10200 (5 oz. tube), or equivalent, to eliminate the air flow escape concern. 5. Before reinstalling the trim, inspect the insulator mat that is mounted on the body rear inner panel to ensure the access flap is fully seated/closed as shown above. 6. Reinstall the trim panels and rear seat. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Correction #2 Note This repair is ONLY for 2010 models that have the original body rear panel insulator (pictured above) and exhibit a higher noise penetration into the cab, when compared to a similarly equipped 2009, or earlier, model. Note that the insulator shape is flat across the bottom edge. Tip Before any repairs, you can visually verify which insulator the vehicle has by looking under the rear seat on the right or left side. If you can see the body Page 16918 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 17057 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 22836 Front Door Weatherstrip: Service and Repair Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Side Door Bottom Auxiliary Sealing Strip Replacement Page 21003 1. Install the door upper striker (4). 2. Install the spacer, if equipped. 3. Install the door upper striker bolt (3). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. Notice: Refer to Fastener Notice. 5. Tighten the upper striker bolts. Tighten the door upper striker bolts to 24 N.m (18 lb ft). 6. Install the upper trim door upper striker cover. Ensure that the retainer clips were Not damaged when removed. Push upward into locator holes. Page 2968 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 305 Memory Seat Module X7 (AN3) Headlamp Switch Replacement (with RPO SLT) Headlamp Switch: Service and Repair Headlamp Switch Replacement (with RPO SLT) Headlamp Switch Replacement (with RPO SLT) Page 10109 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Clip the line assembly to the frame. 3. Tighten the BPMV bolts. 4. Install the fuel/EVAP line bracket locator tab to the frame. 5. Install the fuel/EVAP line clips to the frame and crossmember. 6. Clip the inline electrical connector to the bracket. Notice: Refer to Fastener Notice. 7. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 N.m (80 lb in). 8. Install the fuel/EVAP line clip nut (2). Tighten the nut to 20 N.m (15 lb ft). 9. Remove the caps from the fuel and EVAP lines. 10. Connect the fuel tank EVAP line quick connect fitting to the chassis line. 11. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Brake Master Cylinder Pressure Sensor (JL1) Brake Master Cylinder Pressure Sensor (JL1) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 12806 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 19094 Seat Belt Tensioner: Removal and Replacement Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Page 5863 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Campaign - Front And Rear Chrome Interior Door Handle Technical Service Bulletin # 09239A Date: 100825 Campaign - Front And Rear Chrome Interior Door Handle SPECIAL COVERAGE Bulletin No.: 09239A Date: August 25, 2010 Subject: 09239A - Special Coverage Adjustment - Front and Rear Chrome Interior Door Handle Lever Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL Equipped with Chrome Interior Door Handles Supercede: The Parts Information section has been revised to include a note that P/N 88880051 is used for the front and rear doors. Step 6 under the Rear Side Door Inside Handle Replacement procedure has also been revised to refer technicians to the Rear Side Door Inside Handle Replacement in SI.Please discard all copies of bulletin 09293, issued July 2010. Condition Some customers of 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles may comment about peeling on the top surface of the front or rear chrome interior door handle(s). A chrome plating irregularity combined with direct sunlight exposure may cause the plating to separate from the top surface of the handle on certain vehicles. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership or mileage. Dealers are to replace the front and/or rear chrome interior door handle levers if signs of peeling are present. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after July 16, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to July 16, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles built within the following VIN breakpoints: Page 15389 Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Tools Required j 45405 Pipe Flaring Tool Kit Caution: Refer to Brake Fluid Irritant Caution. Caution: Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Important: When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the J 45405. * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Important: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 6. Using the pipe cutter included in the J 45405, carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. Page 957 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 17090 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 6232 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 12681 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 17706 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Page 22715 Air Dam: Service and Repair Front Air Deflector Replacement (Chevrolet) Front Air Deflector Replacement (Chevrolet) Page 23017 Cruise Control: Description and Operation Cruise Control Description and Operation Cruise control is a speed control system that maintains a desired vehicle speed under normal driving conditions at speeds above 40 km/h (25 mph). Steep grades may cause variations in the selected vehicle speeds. The following are the main components of the Cruise Control System: * The accelerator pedal * The stop lamp switch * The body control module (BCM) * The cruise control switches * The engine control module (ECM) * The throttle actuator control (TAC) motor * The vehicle speed sensor (VSS) Cruise Control Engaged The Cruise Control System will engage and adjust vehicle speeds, based on the activation of the following cruise control switches, which are located on the steering wheel: * The on/off switch * The + RES switch * The - SET switch The body control module (BCM) monitors the signal circuit of the cruise control switches. The BCM relays the cruise control switch status to the engine control module (ECM) via the GMLAN serial data circuit. The ECM uses the status of the cruise control switch to determine when to capture and maintain the vehicle speed. The ECM monitors the vehicle speed signal circuit in order to determine the desired vehicle speed. The ECM uses the throttle actuator control (TAC) motor in order to maintain the vehicle speed. For further information on the TAC System, Refer to Throttle Actuator Control (TAC) System Description. Voltage is supplied to the cruise control switch via the steering wheel control switch reference voltage circuit supplied by the BCM. The cruise control function switches are arranged in a resistive ladder design, with each cruise control function switch having a different resistance value. The BCM detects a specific voltage value that is associated with the cruise control function switch being activated. When the normally open cruise control on/off switch is turned ON, the switch closes and the BCM supplies a ground to the cruise control switch ON indicator circuit as it becomes illuminated. The BCM sends a GMLAN serial data message to the ECM indicating that the on/off switch is active. Similarly, when the normally open + RES switch or the normally open - SET switch are pressed, the switch closes and the BCM detects the predetermined voltage signal on the cruise control set/coast and resume/accel switch signal circuit. The BCM sends a GMLAN serial data message to the ECM indicating that the + RES switch or the - SET switch is active. To engage the Cruise Control System, ensure that the vehicle speed is above 40.2 km/h (25 mph), turn the cruise On/Off switch ON and momentarily press the - SET switch. The ECM will engage the Cruise Control System and record the vehicle speed. The ECM sends a GMLAN serial data message to the driver information center (DIC) in order to illuminate the CRUISE SET TO ### message. The ECM sends a GMLAN serial data message to the instrument panel cluster (IPC) in order to illuminate the Cruise Engaged indicator in the IPC. The - SET switch and the + RES switch will remain inactive when the BCM has not received the predetermined voltage signal from the on/off switch. Pressing the accelerator pedal, while the Cruise Control System is engaged, will allow the driver to override the Cruise Control System in order to accelerate the vehicle beyond the current set vehicle speed. When the accelerator pedal is released, the vehicle will decelerate and resume the current set vehicle speed. The driver can also override the current set vehicle speed via the SET switch and the + RES switch. When the Cruise Control System is engaged, pressing and holding the - SET switch will allow the vehicle to decelerate from the current set vehicle speed without deactivating the Cruise Control System. When the - SET switch is released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed. When the Cruise Control System is engaged, momentarily pressing the - SET switch will allow the vehicle to decelerate at 1.6 km/h (1 mph) increments for each time that the - SET is momentarily pressed, with a minimum vehicle speed of 37 km/h (23 mph). Pressing and holding the + RES switch, when the Cruise Control System is engaged, will allow the vehicle to accelerate to a greater vehicle speed than the current set vehicle speed. When the + RES switch is released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed. When the Cruise Control System is engaged, momentarily pressing the + RES switch will allow the vehicle to accelerate at 1.6 km/h (1 mph) increments for each time that the + RES switch is momentarily pressed, with the maximum acceleration total of 16 km/h (10 mph) over the current set vehicle speed. Momentarily activating the + RES switch will recall the previous vehicle speed, after the cruise control system is disengaged by pressing the brake pedal or by activating the CANCEL switch. Cruise Control Disengaged The engine control module (ECM) disengages the cruise control operation based on the signals from the following switches: * The stop lamp switch * The cruise control On/Off switch * The cruise control cancel switch Page 6450 Page 9335 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 11923 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 15104 Transmission Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Turbine Speed Sensor Page 15051 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 14356 Page 3948 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 2825 Page 1142 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 11442 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 9806 Transmission Position Switch/Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 19374 Parking Assist Distance Sensor: Locations Object Detection Component Views Rear of the Vehicle (X88) 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Backup Lamp - Right Rear 4 - Tail/Stop and Turn Signal Lamp - Lower Right 5 - Object Sensor Right Rear Corner (UD7) 6 - License Lamp - Right 7 - Object Sensor - Right Rear Middle (UD7) 8 Marker Lamp - Tailgate (R05) 9 - Object Sensor - Left Rear Middle (UD7) 10 - License Lamp - Left 11 - Object Sensor - Left Rear Corner (UD7) 12 - Tail/Stop and Turn Signal Lamp - Lower Left 13 Backup Lamp - Left Rear Rear of the Vehicle (Z88) Page 17150 Junction Block - Left I/P X10 Junction Block - Left I/P X11 Page 22128 Memory Seat Module X3 (AN3) Page 5836 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Audio System - Poor AM and FM Band Reception Antenna Cable: Customer Interest Audio System - Poor AM and FM Band Reception TECHNICAL Bulletin No.: 06-08-44-033B Date: August 25, 2008 Subject: Radio - Poor AM and FM Reception (Inspect and Fully Seat Connector) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to clarify the location of connector C213 for the Yukon Denali. Please discard Corporate Bulletin Number 06-08-44-033A (Section 08 - Body & Accessories). Condition Some customers may comment that the radio has poor AM and FM reception. Cause The radio antenna coax cable may not be fully seated at connector C213. Correction 1. Remove the driver and passenger windshield pillar garnish molding (A-pillar trim) and disconnect the wiring harness. 2. Remove the instrument panel upper trim panel and disconnect the electrical connections. 3. Remove the foam tape surrounding the radio coax cable electrical connector C213. Connector C213 is located under the top left side of the instrument panel upper trim panel on all vehicles except the Cadillac Escalade EXT and the Chevrolet Avalanche. Connector C213 is located under the top right side of the instrument panel upper trim panel on the Cadillac Escalade EXT, Chevrolet Avalanche and GMC Yukon Denali. 4. Inspect connector C213 and manipulate coax as needed to ensure that the connector is fully seated (The above graphic shows the connector properly seated). 5. Install foam tape around connector C213. 6. If re-securing the connector does not correct the condition, refer to SI for further diagnosis and repair. 7. Install the instrument panel upper trim panel and electrical connections. 8. Install the driver's and passenger's windshield pillar garnish moldings (A pillar trim) and electrical connectors. Warranty Information Page 14047 Right Side Control Valve Body Assembly Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Disassembly/Reassembly If a valve is restricted by a metal burr from machining that bore, remove the valve and burr, then inspect movement in the valve's normal position. If no Page 15293 1. Release the park brake. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . 4. Remove the hub and rotor assembly. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement . 5. Mark the relationship of the hub to the rotor. 6. Place the hub and rotor assembly on a hydraulic press. 7. Press the wheel studs out of the hub and rotor assembly. 8. Separate the hub from the rotor. Installation Procedure 1. Align the hub and the rotor. 2. Install each of the new wheel studs into the hub and rotor assembly by performing the following: 1. Install the stud. 2. Install 4 washers to the stud. 3. Install a lug nut to the stud with the flat side of the nut toward the washers. 4. Tighten the lug nut to draw the stud into the hub and rotor assembly. 5. Inspect the hub and rotor assembly to ensure the stud is seated completely. 6. Remove the lug nut and the washers. 3. Install the hub and rotor assembly to the vehicle. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement . 4. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . 5. Lower the vehicle. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 2919 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 11459 Crankshaft Position Sensor: Connector Views Engine Controls Connector End Views Crankshaft Position (CKP) Sensor Page 10272 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 6124 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 2364 View of the connector when released from the component. View of another type of Micro 64 connector. Page 12185 Page 15412 Page 4777 1. Install the air cleaner outlet resonator to the MAF/IAT sensor and throttle body. Notice: Refer to Fastener Notice. 2. Tighten the air cleaner outlet resonator clamp (2) at the throttle body. Tighten the clamp to 4 N.m (35 lb in). 3. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). 4. Connect the PCV hose (1) to the air cleaner outlet resonator. Page 19594 Garage Door Opener Transmitter: Description and Operation Garage Door Opener Description and Operation (Three LEDs) Garage Door Opener Description and Operation (Three LEDs) The garage door opener (GDO) is located in the overhead console or drivers side sunshade. If battery voltage is lost due to a condition such as a dead battery, the GDO unit relies on the non-serviceable internal power backup supply. The GDO is fixed and rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the GDO to change every time the GDO is used within operating range of the receiver. Rolling code programming requires the customer to push a learn/program button on the GDO receiver at their home. This button is usually located on the receiver unit under a cover (light cover) on one end of the unit. The customer must follow the GDO manufacturers instructions to program/learn the receiver to accept the Universal Home Remote System as an authorized opener for their unit. When the receiver and the GDO are initially programmed together, a code is established and a new code is created for every new transmission. The software in the receiver recognizes the GDO and accepts the new code. The GDO is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, refer to 1-866-572-2728. The GDO is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters. Refer to Programming and Relearning for setup and programming. See: Testing and Inspection/Programming and Relearning The GDO has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 GDOs, security gates, and lighting systems. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Page 11026 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 469 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 19550 3. Inspect the wiring harness for damage or improper routing near drivers side rear screw hole. Refer to the above graphic (callout # 1 shows proper routing callout # 2 indicates improper routing). 4. Repair the wiring harness as necessary. If the wiring harness is not damaged refer to SI for diagnosis and repair of the system. 5. Install the DVD screen and the four retaining screws. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Windshield Outside Moisture Sensor Replacement Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Replacement Windshield Outside Moisture Sensor Replacement Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 12715 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 2279 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 14389 Interior - Proper Use of Floor Mats Carpet: All Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Page 9417 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Tank Pressure Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 8346 Body Control Module (BCM) X3 Page 12749 Page 2681 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7012 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 3007 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 6947 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 3938 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. HVAC - Automatic Low Pressure Sensor / Switch: Diagrams HVAC - Automatic HVAC Connector End Views A/C Low Pressure Switch Reverse Lockout Solenoid Page 17859 Transmission Support Crossmember Replacement (2WD 1500/2500) Transmission Support Crossmember Replacement (2WD 1500/2500) Page 466 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 14862 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 16260 Fuse Block - I/P X1 Page 6317 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 12613 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 21864 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 16441 Page 24140 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Remove the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Important: DISCARD the old steering shaft lock plate ring. 2. Remove the following parts from the steering shaft: 1. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137. 2. Turn signal switch cancel cam position plate (2) 3. Turn signal switch cancel cam (3) Installation Procedure Page 15290 Rear Brake Rotor Replacement (JH6) Rear Brake Rotor Replacement (JH6) Page 24216 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 972 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 6614 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 10190 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 4122 Page 10945 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 13698 6. Remove the cable end from the steering column ball stud. 7. Depress the tangs and remove the cable from the steering column bracket. Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 8. Remove the range selector cable from the support. 9. Remove the cable grommet from the floor panel. 10. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 11. Remove the clips on the cable from the floor panel reinforcement. 12. Ensure the transmission manual shaft is positioned in mechanical park. 13. Remove the cable clip on the transfer case, if equipped. Page 16050 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2720 Vehicle Zoning Strategy Truck Zoning Page 17102 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Fog Lamp Switch Replacement (with RPO SLT) Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (with RPO SLT) Fog Lamp Switch Replacement (with RPO SLT) 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Filter - A/T: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the catalytic converter. 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. Page 3206 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Page 2555 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 4087 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 16060 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 19433 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 12479 Clutch Control Solenoid Valve: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Locations Air Flow Meter/Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 2912 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 11246 Camshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 4131 Junction Block - Left I/P X10 Junction Block - Left I/P X11 Page 6058 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 14187 6. Install the pinion into the pinion gear bearing retainer. 7. Install the outer pinion bearing onto the pinion. 8. Install a new pinion oil seal using the J 44414. 9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 10. Install the pinion yoke. Align the marks made during removal. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 12. Install the washer and a new pinion nut. 13. Install the J 8614-01 onto the pinion yoke as shown. Notice: Refer to Fastener Notice. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 14. Tighten the pinion nut while holding the J 8614-01. Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Pressure Regulator Replacement Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Page 10275 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 19283 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Service and Repair Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Caution: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Notice: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents. Vehicle Lifting * Ensure that the lifting equipment meets weight requirements and is in good working order. Always follow the lift manufacturer's instructions. * You may lift and support the front of the vehicle at the front suspension near the wheel assemblies. Ensure that the arms of the front cradle are extended as close to the steering knuckle as possible. * Ensure that the vehicle is centered on the hoist before attempting to lift. * When using a suspension-contact hoist, ensure that the rear cradle has adequate clearance for the rear stabilizer bar. Page 8438 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 9552 Manifold Pressure/Vacuum Sensor: Diagrams Engine Controls Connector End Views Manifold Absolute Pressure (MAP) Sensor Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 13237 Note Only on 4T65E, the second magnet (left) should be attached to the transmission filter. If the magnet is attached in any other location, it may cause interference (refer to graphic above). 4L60 Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Page 3927 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 8426 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Locations Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 12168 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (367A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Page 5063 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Locations Hood Sensor/Switch (For Alarm): Locations Immobilizer Component Views Near the Hood Latch 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor - ISRVM Page 9875 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 22960 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 5951 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 11019 Page 16447 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) Page 2019 Page 15287 Page 3977 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 8105 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 5602 Disclaimer Page 12967 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 2196 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 9668 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 4450 Notice: Refer to Fastener Notice. 4. Install the rocker arms as follows: 1. Finger start the bolt at location (1) 2. Finger start the bolt at location (2) 3. Finger start the bolt at location (3) 4. Finger start the remaining rocker arm bolts 5. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57-63 degrees clockwise or counterclockwise from the engine front cover alignment tab (2). Important: Once the rocker arms are installed and properly torqued, no additional valve lash adjustment is required. 6. Tighten the rocker arm bolts. Tighten bolts to 30 N.m (22 lb ft). 7. Install the rocker arm cover. Page 1837 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 6106 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 6598 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 5224 7. Remove the fan shroud bolts 8. Remove the upper fan shroud. Installation Procedure 1. Install the upper fan shroud. Notice: Refer to Fastener Notice. 2. Install the fan shroud bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Install the fan shroud retainers. 4. If equipped install the inlet radiator hose retainer to the fan shroud 5. If equipped install the throttle body heater hose retainer to the fan shroud. Page 16775 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 11139 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 8586 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9078 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 9924 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 1068 Page 8279 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 13911 Transmission Position Switch/Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 4921 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 4735 8. Remove the balance shaft retainer bolts and retainer. Important: The balance shaft and the balance shaft front bearing are serviced only as a package. Do not remove the balance shaft front bearing from the balance shaft. 9. Use a soft-faced hammer in order to remove the balance shaft from the engine block. 10. Clean and inspect the balance shaft, if necessary. Refer to Balance Shaft Cleaning and Inspection. Installation Procedure Important: The balance shaft drive and balance shaft driven gears are serviced as a set. The set includes the balance shaft driven gear bolt. 1. Apply clean engine oil to the balance shaft front bearing. 2. Using J 36996 and J 8092, install the balance shaft. Notice: Refer to Fastener Notice. 3. Install the balance shaft retainer and bolts. Tighten the bolts to 12 N.m (106 lb in). Page 22941 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Navigation Radio - Various Malfunctions Navigation System: Customer Interest Navigation Radio - Various Malfunctions TECHNICAL Bulletin No.: 08-08-44-002B Date: April 14, 2009 Subject: Navigation Radio Clock and/or Clock Tab Do Not Appear or Disappears Intermittently, Split Screen, Points of Interest or Exit List Appears While Driving, Text Color May Be Difficult to See, Address Book Characters May Be Hard to Find, Cannot Scroll Through XM Radio Categories, I Agree Screen Lockouts (Update Navigation Radio with New Software) Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008 HUMMER H2 with Navigation Radio RPO UVB or U3U Supercede: This bulletin is being revised to add additional customer concerns and to update the list of Operating Characteristics the software addresses. Please discard Corporate Bulletin Number 08-08-44-002A (Section 08 - Body & Accessories). Condition Some customers may comment about any of the following conditions: - The clock and/or clock tab does not appear or disappears intermittently on the navigation screen. - A split screen, points of interest or an exit list may appear on the navigation screen while driving. - The text color may be difficult to see on light color backgrounds. - The address book entry characters may be hard to find. - The customer may not have the ability to scroll through the XM radio categories while the vehicle is in motion. - The customer may not be able to scroll through music navigator, MP3 folders, address book, POI's and Turn List when the vehicle is in motion. - "I Agree" screen appears every ignition cycle. - Destination entry screens do not have a "back" button to return to previous page. - Customer is not able to adjust screen brightness while vehicle is in motion. Cause These conditions may be caused by a software anomaly. Correction Using the Tech 2(R), verify that the vehicle is equipped with one of the following radio part numbers: Important If the vehicle is not equipped with one of the following radio part numbers, disregard this bulletin. - 15882766 Page 17954 Wheel Hub: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Page 9405 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 11860 Radiator Hose Quick Connect Fitting Radiator Hose: Service and Repair Radiator Hose Quick Connect Fitting Radiator Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring (3) around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the radiator outlet hose (2) from the quick connector fitting at the radiator (1). Installation Procedure Important: Do not install the retaining ring (3) onto the fitting by pushing the retaining ring down over the fitting. 1. Hook one of the open ends of the retaining ring (3) in one of the slots in the quick connector. 2. Rotate the retaining ring (3) around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 3. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 4. Install the radiator outlet hose (2) onto the radiator quick connector fitting until a click is heard or felt. Pull back on the radiator outlet hose (2) to ensure a proper connection. Locations Windshield Washer Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 15390 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the J 45405, by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Important: Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Important: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405. 11. Install the tube nuts on the brake pipe, noting their orientation. Page 9298 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 15005 Transmission Control Module (TCM), Engine Side Page 17468 The IP wiring branch to C202 (IP to body cam lock connection) may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been seated. Possible point of contact (2). The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been seated. Possible points of contact (1, 2). The IP wiring branch to C202 may have never been secured into place (gray retaining clip (1) off the branch was never seated). Page 5327 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8908 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13494 Transmission Speed Sensor: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Input and Output Speed Sensor (ISS/OSS) Page 8990 Engine Control Module X1 (Pin 1 To 24) Page 6029 Page 17110 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 7226 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Transmission Fluid Temperature Sensor Specifications Page 12920 Page 12890 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 6795 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 617 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 3673 Fluid Filter - A/T: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement Page 6713 Throttle Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 17832 Ball Joint: Service and Repair Lower Control Arm Ball Joint Replacement Removal Procedure Important: The following service procedure applies to vehicle equipped with cast iron lower control arms only. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the lower control arm from the vehicle. 4. Place the lower control arm in a vise. 5. Using a chisel, remove the securing crimps from the ball joint body, if equipped. 6. Using a press, remove the ball joint from the lower control arm. Installation Procedure Important: Use the outer flange of the ball joint in order to press the ball joint into place. 1. Install the ball joint using a press. 2. Place the lower control arm a bench vise. 3. Using a punch, install the crimps to the ball joint, if necessary. Use the replaced ball joint as a reference. 4. Install the lower control arm in the vehicle. 5. Install the tire and wheel. 6. Remove the safety stand and lower the vehicle. 7. Verify the wheel alignment. Refer to Wheel Alignment Specifications. Page 3681 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections Page 10919 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12548 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 11268 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 16954 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 24071 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 17355 X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) (+U42) Page 4649 5. If equipped with 2-wheel drive (2WD), remove the crossmember bolts and bar. 6. If equipped with 4-wheel drive (4WD), remove the crossmember bolts and bar. 7. If equipped with 4WD, remove the front differential carrier. Refer to Differential Carrier Assembly Replacement (1500 FWD) Differential Carrier Assembly Replacement (2500 4WD). 8. Remove the engine harness bracket bolts. 9. Remove the starter. 10. Remove the transmission cover. Page 9799 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 1371 Driver Door Switch (DDS) X3 (AN3/DL3) Page 20270 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4930 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 1907 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Page 8251 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 1638 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 15078 Transmission Mode Switch: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Internal Mode Switch (IMS) Internal Mode Switch (IMS) Page 13479 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 16694 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Important: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Fuel System - Revised Fuel Injector Diagnosis Fuel Injector: All Technical Service Bulletins Fuel System - Revised Fuel Injector Diagnosis Bulletin No.: 06-06-04-064 Date: November 29, 2006 SERVICE MANUAL UPDATE Subject: Revised Fuel Injector Diagnosis (w/J 39021 or w/Tech 2(R)) Models: 2007 Chevrolet Cobalt, HHR, Silverado 2007 GMC Sierra 2007 Pontiac G5 with 2.2L (VIN F - RPO L61) or 4.3L (VIN X - RPO LU3) Engine This bulletin is being issued to revise the Fuel Injector Diagnosis (w/J 39021 or w/Tech 2(R)) in the Engine Controls sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information. The following information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Please be advised that the Fuel Injector Balance Test with the Tech 2(R) is NOT available for the vehicles listed above. You must use the Fuel Injector Balance Test with special tool J 39021. You may also use the Fuel Injector Diagnosis (w/CH-47976) procedure if you have access to the CH-47976 Active Fuel Injector Tester. Follow the on-screen instructions for connecting the CH-47976 Active Fuel Injector Tester to the subject vehicle. Disclaimer Page 19143 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11681 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 21071 Page 17579 Alignment: Specifications Trim Height Specifications Trim Height Specifications Trim Height Specifications Page 11080 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 11207 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 8344 Body Control Module (BCM) X1 Page 7562 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6503 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 12948 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 20021 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 1821 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 12710 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Drivetrain - Bump/Clunk Noise at Stop Or From Launch Drive/Propeller Shaft: Customer Interest Drivetrain - Bump/Clunk Noise at Stop Or From Launch TECHNICAL Bulletin No.: 09-04-17-002E Date: January 14, 2011 Subject: Bump Feel/Clunk Noise at Stop or from Launch (Clean/Lubricate Propeller Shaft Slip Yoke Splines) Models: 2007-2008 Chevrolet Avalanche, Suburban 2007-2009 Chevrolet Tahoe 2007-2010 Chevrolet Silverado (New Body Style) with Single-Piece Propshafts 2007-2008 GMC Yukon XL 2007-2009 GMC Yukon 2007-2010 GMC Sierra (New Body Style) with Single-Piece Propshafts All Equipped with 4L60 Automatic Transmission (RPO M30) and 2WD Attention: This bulletin contains a procedure to clean/lubricate the slip yoke splines and replace the slip yoke, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the slip yoke. Supercede: This bulletin is being revised to update the warranty statement. Please discard Corporate Bulletin Number 09-04-17-002D (Section 04 - Driveline/Axle). Condition Some customers may comment that the vehicle has a bump feel or a clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind. Cause This condition may be caused by a slip/stick condition in the interface between the rear propshaft slip yoke and the transmission output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transmission while the vehicle rebounds slightly backward after stopping its momentum and create this condition. Correction Note Do not use the grease from this bulletin for lubrication of the slip yoke splines on 2WD MYC 6 Speed Transmissions or any 4WD vehicles. The output shaft in a 2WD MYC 6 Speed Transmissions or a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transmission or the transfer case and mixing with the fluid inside. The new grease is not compatible with the automatic transmission fluid (ATF) and can cause damage if mixed. Please refer to Corporate Bulletin Number 09-04-21-003B for repairing the bump feel or clunk noise condition on 4WD vehicles. Note A bump feel or noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic. Verify the customer's concern. Clean/Lubricate Slip Yoke Splines 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 2. Inspect the rear slip yoke splines on the drive shaft. 3. Clean the slip yoke splines with brake cleaner or equivalent and a shop towel. 4. Assure the yoke is free of rust or other foreign material. 5. Lubricate the slip yoke spline with grease, P/N 19257121 (in Canada, 19257122), using a brush or swab to completely cover the entire spline with a light coating of grease. Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Disconnect the engine wiring harness electrical connector (4) from the crankshaft position (CKP) sensor. Page 7129 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 11131 Page 22585 1 - Outside Rearview Mirror - Passenger 2 - Door Lock Switch - Passenger (AU3 -AN3/DL3) 3 Passenger Door Switch (PDS) (AN3/DL3) 4 - Door Latch Assembly - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) 6 - Speaker - Right Front 7 - Window Motor - Passenger (A31) 8 - Window Switch - Passenger (A31 -AN3/DL3) 9 - Heated Seat Switch Passenger (AN3) Driver Door (AU3 -AN3/DL3) Page 6477 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 11374 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 7368 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 3296 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Page 3915 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 1877 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Allison - Automatic Transmission Transmission Mode Switch: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Transmission Internal Mode Switch Page 18146 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Page 14175 Pinion Flange: Service and Repair Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle w/Drum Brakes) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle w/Drum Brakes) Tools Required * J 8614-01 Flange/Pulley Holding Tool * J 22388 Rear Axle Pinion Oil Seal Installer - Rear Removal Procedure Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 3. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 4. Using an inch-pound torque wrench, measure the amount of torque required to rotate the pinion. Record this measurement for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion oil seal * The differential case bearings * The axle bearings * The axle seals Page 1787 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Sunroof Opening Trim Finish Lace Replacement (Extended Cab) Removal Procedure 1. Beginning at the joint located in the center rear of the lace of the sunroof opening, pull the sunroof finishing lace from the sunroof window track assembly. 2. Remove the sunroof finishing lace from the track. Installation Procedure 1. Position the end of the sunroof finishing lace at the center rear of the sunroof opening. Page 17350 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) Page 4589 Engine Mount: Service and Repair Engine Mount Replacement - Right Engine Mount Replacement - Right Side Removal Procedure Notice: Refer to Engine Mounting Notice. 1. From under the hood, remove the engine mount to engine mount bracket bolts. (left side shown, right side similar). 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the oil pan skid plate bolts and plate. Notice: Refer to Engine Lifting Notice. 4. Using an adjustable jack on the square tab (left side shown) at the rear of the engine block, raise the engine. In order to access the square tab, remove the starter. (left side shown, right side similar). Refer to Starter Motor Replacement (4.3L) Starter Motor Replacement (4.8L, 5.3L, 6.0L, and 6.2L) Starter Motor Replacement (6.6L). Page 12 Central Control Module: Diagrams Entertainment/Communication Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Page 4170 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 11666 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Tools Required * J 22794 Spark Plug Port Adapter * J 38606 Valve Spring Compressor * J 5892-D Valve Spring Compressor * J 42073 Valve Stem Oil Seal Installer Removal Procedure 1. Remove the required valve rocker arms. 2. Remove the required spark plugs. 3. Install the J 22794 into the spark plug hole. 4. Connect a shop air supply hose and apply compressed air in order to hold the valves in place. 5. Install a flat washer onto the removed rocker arm bolt. 6. Install the bolt and rocker arm for the valve spring requiring removal. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 7. Using J 5892-D compress the valve spring. 1. Hook the slotted end of J 5892-D under the washer on the rocker arm bolt. 2. Apply steady pressure on the valve spring cap until the valve keys are accessible. Page 10799 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 591 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 3822 perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes Pressure Hydraulic Brake System Bleeding (Pressure) Tools Required * J 29532 Diaphragm Pressure Bleeder, or equivalent * J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. Page 4915 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 9888 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13488 Transmission Speed Sensor: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 8175 Engine Control Module X2 (Pin 1 To 30) Page 3682 * The areas surrounding the connections Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap. Page 7278 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 13694 8. Install the retainer securing the cable to the steering column. 9. Position the carpet and insulation around the driver's area. 10. Install the instrument panel knee bolster. 11. Raise and support the vehicle. Refer to Vehicle Lifting. 12. Install the cable clips (2) to the transfer case, if equipped. Page 21829 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Locations Power Door Lock Switch: Locations Vehicle Access Component Views Driver Door 1 - Door Frame 2 - Window Switch - Driver (A31 -AN3/DL3) 3 - Outside Rearview Mirror - Driver 4 Memory/Heated Seat Switch (AN3) 5 - Outside Rearview Mirror Switch (DL8/DPN) 6 - Driver Door Switch (DDS) (AN3/DL3) 7 - Speaker - Left Front 8 - Window Motor - Driver (A31) 9 - Door Lock Switch - Driver (AU3 -AN3/DL3) 10 - Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) 11 - Door Latch Assembly - Driver Passenger Door Page 8647 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (2) from the HO2S pigtail electrical connector (1). 4. Remove the HO2S pigtail electrical connector clip from the engine wiring harness clip (3). 5. Remove the HO2S (3). Page 7960 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Navigation Radio - Weak Or No GPS Signal Information Navigation System: All Technical Service Bulletins Navigation Radio - Weak Or No GPS Signal Information INFORMATION Bulletin No.: 08-08-44-027 Date: August 12, 2008 Subject: Information on Navigation Radios that Have a Weak or No GPS Signal Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models with Navigation Radios Some customers may comment on intermittent or no Global Positioning System (GPS) signal reception on the Navigation radio. The GPS signal reception icon on the map screen may have a red line through it. This condition may be caused by aftermarket electronic devices such as radar detectors, cell phones, and MP3 players that may interfere with the GPS signal reception. Aftermarket window tinting or clear UV film applied to the windshield may also reduce the GPS signal reception and cause the Navigation radio to function incorrectly. Recommendations Educate the customer on the GPS antenna location and the need to keep electronic devices away from it. The GPS antenna is located in the upper center of the Instrument Panel. Instruct the customer to move electronic devices away from the GPS antenna. It may also be necessary to remove aftermarket films and tinting from the windshield. Do not replace a Navigation radio that seems to have poor GPS signal reception without considering these possible causes of the concern. Refer to the No Global Positioning System (GPS) Reception diagnostic procedure in SI for more information. Disclaimer Page 5462 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 3134 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 7069 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 5476 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 23199 Compass: Description and Operation Compass Calibration and Magnetic Variance Compass Calibration Before calibrating the compass, drive the vehicle to an open area that is magnetically clean or free of large metallic objects such as high tension power lines or large steel buildings. Verify there are no magnetized roof antennas, magnets on or hanging from the mirror, or any other magnetized objects on the inside or outside of the vehicle close to the mirror. 1. Start the engine. Important: Before calibrating the compass, make sure the mirror has the correct zone number. Refer to Compass Magnetic Variation Adjustment. 2. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or on/off (w/UE1) depending on the type of mirror on the vehicle, until the letter "C" or "CAL" is displayed. 3. Drive the vehicle in circles at a speed of less than 8 km/h (5 mph) until the "C" or "CAL" is replaced by a proper vehicle heading. The calibration procedure is now complete. Compass Magnetic Variation Adjustment Magnetic variation adjustments are required when the compass displays a constant error in heading. Variation is the difference between magnetic north and true north due to geographical location. World Magnetic Variation Map 1. Locate your current geographic location on the World Magnetic Variation Map. 2. Turn ON the ignition, with the engine OFF. 3. Press and hold the switch for the compass, which may be depicted as COMP, COMPASS, or on/off (w/UE1) depending on the type of mirror on the vehicle, until a zone number appears on the compass display. 4. Depress the switch for the compass to select the desired zone number. 5. Wait 5 seconds. The display will return to a compass heading. The variance procedure is now complete. 6. Calibrate the compass. Refer to Compass Calibration mentioned above. Page 17293 X123 X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Page 18218 Air Duct: Service and Repair Floor Air Outlet Duct Replacement - Left Side Floor Air Outlet Duct Replacement - Left Side Removal Procedure 1. Remove the push pin (5) from the left floor air outlet duct (4). 2. Remove the left floor duct (1) from the HVAC module (2). Installation Procedure 1. Install the left floor air outlet duct (1) to the HVAC module (2). 2. Install the push pin (2) to the left floor air outlet duct. Page 2230 View of the connector when released from the component. View of another type of Micro 64 connector. Page 5633 Disclaimer Page 1975 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 1881 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 19376 Parking Assist Distance Sensor: Diagrams Object Detection Connector End Views Object Sensor - Left Rear Corner Object Sensor - Left Rear Middle Page 21908 Memory Seat Module X7 (AN3) Page 5078 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 18373 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11865 4. Remove the CKP sensor bolt and sensor. Installation Procedure Important: When installing the CKP sensor, make sure the sensor is fully seated before tightening the bolt. A poorly seated CKP sensor may perform erratically and may set false diagnostic trouble codes (DTCs). Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CKP sensor, install a NEW O-ring seal onto the sensor. 2. Lubricate the O-ring seal with clean engine oil. Notice: Refer to Fastener Notice. 3. Install the CKP sensor and bolt. Tighten the bolt to 10 N.m (89 lb in). Page 6372 Page 23097 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 5788 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 7010 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 17707 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Place drain pans under the vehicle as needed. Notice: Refer to Power Steering Hose Disconnected Notice. 2. Disconnect the power steering fluid cooler hose clamp and hose (3) from the steering gear (2). 3. Remove the power steering gear outlet pipe (1) from the steering gear (2). Installation Procedure Page 16039 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Specifications Oil Pan: Specifications Oil Pan Bolt and Nut ............................................................................................................................ .......................................................... 25 N.m 18 lb ft Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 10779 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 14575 Tighten the bolt to 11 N.m (97 lb in). 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. Tighten the bolts to 11 N.m (97 lb in). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 22964 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 9835 Page 3394 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Service and Repair Acceleration/Deceleration Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Page 14262 10. Remove the C-lock from the button end of the axle shaft. Important: When removing the axle shaft, do not rotate the shaft. Rotating the shaft will misalign the gears. Misaligning the gears will make assembly difficult. 11. Remove the axle shaft from the housing. Installation Procedure Important: Carefully insert the axle shaft in order to not damage the seal. 1. Install the axle shaft into the rear axle housing. 2. Slide the axle shaft into place allowing the splines to engage the differential side gear. 3. On axles without a locking differential, place the C-lock on the button end of the axle shaft. 4. On axles with a locking differential, keep the pinion shaft partially withdrawn. 5. Install the brake drum. 6. On axles with a locking differential, place the C-lock (1) on the axle shaft (3) so that the ends are flush with the thrust block (2). 7. Pull the shaft flange outward in order to seat the lock in the differential gear. Page 14398 7. Remove the propeller shaft from the vehicle. Installation Procedure 1. Inspect the splines of the slip yoke for a sufficient coating of grease. If the splines of the slip yoke does not have a sufficient coating of grease, lubricate the shaft with grease, GM P/N 12345879 or equivalent, RWD w/ Automatic Transmission Only. 2. Install the propeller shaft into the transmission or transfer case. Align the reference marks made during removal. 3. Install the propeller shaft (3) to the rear axle pinion yoke (4). Align the reference marks made during removal. Notice: Refer to Fastener Notice. 4. Install the yoke retainers (2) and bolts (1). Tighten the yoke retainer bolts to 25 N.m (18 lb ft). 5. Lower the vehicle. Page 7988 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 11687 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 5929 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 2164 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 3764 7. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/4L60-E/4L65-E/4L70-E - Automatic Transmission/Fluid Leak Diagnosis 8. If the fluid level is in the acceptable range, push the dipstick back into the dipstick tube all the way, and then flip the handle down to lock the dipstick in place. 9. If applicable and if the vehicle is equipped, reset the transmission oil life monitor only if the fluid was changed. Fluid Condition Inspection Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the bottom pan for excessive metal particles or other debris. A small amount of "friction" material in the bottom pan is a "normal" condition. If large pieces and/or metal particles are noted in the fluid or bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic Procedures/4L60-E/4L65-E/4L70-E - Automatic Transmission/Engine Coolant/Water in Transmission Page 24711 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 16011 Page 8588 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 14623 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 17152 Junction Block - Left I/P X13 (AN3) Page 2638 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 4504 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections Page 5797 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 3017 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 19703 Page 13686 8. Install the retainer securing the cable to the steering column. 9. Position the carpet and insulation around the driver's area. 10. Install the drivers seat. 11. Install the instrument panel knee bolster. 12. Raise and support the vehicle. Refer to Vehicle Lifting. 13. Align and install the cable to the bracket. 14. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). 15. Install the cable clip on the transfer case, if equipped. 16. Install the retainer that secures the cable to the bracket. Page 12527 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 20599 For vehicles repaired under warranty, use the table above. Disclaimer Page 12848 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 5397 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 11015 Page 3074 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 11740 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 2090 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 17063 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 5072 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 15956 Auxiliary Power Outlet: Tools and Equipment Special Tools Page 7029 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 9856 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5180 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7640 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 2951 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 15239 Brake Pad: Service and Repair Front Disc Brake Pads Replacement (JH6, JH7) Front Disc Brake Pads Replacement (JH6, JH7) Page 16046 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 578 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 24520 Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved. - GM dealers and Canadian Saturn/Saab retailers should use GMVIS. - Saturn US retailers should use the 'Investigate Vehicle History' link on the Global Warranty Management application within DealerWorld. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. - US GM and Saturn dealers/retailers - GM DealerWorld Recall Information - Canadian GM/Saturn/Saab dealers/retailers - GMinfoNet Recall Reports - Export dealers - sent directly to dealers The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information GM, Saturn Canada Only: Parts required to complete this recall are to be obtained from General Motors Service and Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. This part is not eligible for RIM Management. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Saturn US Only: A pre-shipment of the required parts to perform this recall has been sent to involved Saturn US retailers from Saturn Service Parts Operations (SSPO). Jumper Harness with In-Line Fuse Page 7143 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 4682 13. Remove the engine harness clamp (1) from the bracket. 14. Disconnect the oil pressure sensor electrical connector (2). 15. Remove the engine wiring harness bracket bolt (1). Page 4562 Drive Belt: Service Precautions Belt Dressing Notice Notice: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Page 19894 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 10627 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 12652 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 7431 5. Remove the knock sensor bolt and sensor. Installation Procedure Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). Page 12685 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 8645 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer. 3. Disconnect the HO2S pigtail electrical connector (5) from the engine wiring harness electrical connector (4). 4. Remove the HO2S (2). Installation Procedure A/C - Does Not Cool/Can't Change Mode/DTC's Set Multiple Junction Connector: Customer Interest A/C - Does Not Cool/Can't Change Mode/DTC's Set Bulletin No.: 07-01-38-009B Date: November 28, 2007 TECHNICAL Subject: EI07264 - Manual HVAC, Temperature or Mode Actuator Performance, A/C Does Not Cool, Unable to Change Mode, DTC B0228, B0413, B0423, B0433, B3779, B3782 (Diagnose for Intermittent Wiring Connection at RH BEC) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Extended and Crew Cab Models Only with Manual Temperature Control HVAC System (RPO C67) Supercede: This bulletin is being revised to end the need for engineering information and to provide diagnostic procedures to accurately diagnose this condition. Please discard Corporate Bulletin Number 07-01-38-009A (Section 01 - HVAC). Condition This concern only applies to Extended or Crew cab vehicles. If the customer did not bring their vehicle in for this concern, do no proceed with this bulletin. Some customers may comment that the A/C blows hot air or is inoperative. They may also comment that they are unable to change the temperature or HVAC mode of the vehicle. Under these conditions, the actuator has moved to a default position. Refer to the table. Cause Page 9947 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 7652 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 11835 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 18780 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended Cab +ASF) Page 6453 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 5724 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Fog Lamp Switch Replacement (with RPO SLT) Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (with RPO SLT) Fog Lamp Switch Replacement (with RPO SLT) Page 17143 Junction Block - Left I/P X1 (Pin M2 To P5) Junction Block - Left I/P X2 Page 13683 14. Remove the retainer securing the cable to the steering column. 15. Remove the cable end from the steering column ball stud. 16. Depress the tangs and remove the cable from the steering column bracket. Page 2752 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 2045 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 11121 Throttle Body: Removal and Replacement Throttle Body Assembly Replacement Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (2) from the throttle body. 3. Remove the throttle body bolts. 4. Remove the throttle body and gasket. Discard the gasket. Installation Procedure Page 3112 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Electronic Brake Control Module (JL4) Electronic Brake Control Module: Diagrams Electronic Brake Control Module (JL4) Electronic Brake Control Module (JL4) Page 605 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 12161 Shift Solenoid: Connector Views 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Page 21604 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Locations Parking Brake Warning Switch: Locations Hydraulic Brake Component Views 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Service and Repair Center Support: Service and Repair Propeller Shaft Center Support Bearing Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the propeller shaft. 3. Remove the center bearing by doing the following: 1. Stand the propeller shaft (2) on end in the press (1) with the center bearing (3) supported by the press bars (4). 2. Press the propeller shaft (2) down and off the center bearing (3). Installation Procedure 1. Install the center bearing (3) onto the propeller shaft (2) by pressing the center bearing onto the shaft using a press (1). 2. Install the propeller shaft. 3. Lower the vehicle. Page 16019 Page 3140 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 19521 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 4719 Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 8. Use J 38606 when J 5892-D will not fit. 9. Remove the valve keys (1). 10. Carefully release the valve spring tension. 11. Remove the J 5892-D or the J 38606. 12. Remove the valve spring cap (2) and valve spring (3). 13. Remove the valve stem oil seal (4). Installation Procedure Important: The exhaust valve oil stem seal has the letters EX (1) molded into the top of the seal. The exhaust valve oil stem seal material is brown in color (2) with a white stripe (3) painted onto the outside diameter of the seal, or the material may be red in color (2) with no paint stripe. The intake valve oil seal is black in color. 1. Assemble the valve into the proper valve guide. 2. Select the proper valve stem oil seal for the specific valve guide. 3. Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil. 4. Assemble the valve stem oil seal onto the valve stem. Page 23940 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 9035 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 5213 lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If re-installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. Notice: Refer to Fastener Notice. 2. Install the ECT sensor to the cylinder head. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 10189 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Application and ID Hazard Warning Flasher: Application and ID This vehicle does not use a traditional hazard/turn signal flasher. This function is controlled by the Body Control Module (BCM). Page 15924 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 22893 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Extended Cab) Sunroof Window Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Remove the sunroof window. 2. Carefully remove the sunroof window weatherstrip (2) from the perimeter of the sunroof window (1). Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window. 3. Ensure that the sunroof does not have any air or waterleaks. Page 20933 Rear Door Hinge: Service and Repair Rear Side Door Hinge Replacement (Extended Cab) Rear Side Door Hinge Replacement (Extended Cab) Page 1136 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 7961 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 11820 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Electrical - No Start/No Crank/Int Electrical Operations Multiple Junction Connector: Customer Interest Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 1318 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 24240 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 16910 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 12907 Shift Solenoid 3 (SS3) Page 981 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 12605 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 6327 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 17913 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Page 21128 Endgate Emblem/Nameplate Replacement (Cheyenne or Silverado) Endgate Emblem/Nameplate Replacement (Cheyenne or Silverado) Page 2648 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 8149 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1942 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Locations Ambient Temperature Sensor / Switch HVAC: Locations HVAC Component Views Ambient Air Temperature Sensors 1 - Radiator Core Support 2 - Ambient Air Temperature Sensor (DF5) 3 - Ambient Air Temperature Sensor - HVAC (CJ2) Page 6330 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 1813 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 21144 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Page 2777 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 8971 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 6055 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 3607 Step 17 - Step 20 Page 2033 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 6661 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 21583 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 22491 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 2758 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 21002 Rear Door Striker: Service and Repair Door Striker Replacement (Extended Cab, Upper) Door Striker Replacement (Extended Cab, Upper) Removal Procedure Important: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the upper trim door upper striker cover (2). Pullstraight downward for the trim cover to release, retained by retainer clips (1). 2. Remove the door upper striker bolts (3). 3. Remove the spacer, if equipped. 4. Remove the door upper striker (4). Installation Procedure Diagram Information and Instructions Fuse: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 4923 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 9177 View of the connector when released from the component. View of another type of Micro 64 connector. Page 7313 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 13433 12. Inspect the transmission fluid pressure manual valve position switch assembly for the following conditions: * Damage * Debris * Damaged or missing O-rings * Cracked connector * Loose electrical terminals * Poor terminal retention 13. Remove the manual detent spring bolt. 14. Remove the manual detent spring. 15. Inspect the manual detent spring for cracks or damage. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 16. Remove the remaining valve body bolts. Page 9747 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 24676 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 4979 Electrical Specifications Fuel Injector: Electrical Specifications Fuel Injector Resistance....................................................................................................................... ..................................................................11-14 Ohms Page 11219 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 404 Trailer Brake Control Module: Diagrams Trailer Brake Controller Module (TBCM) Electronic Suspension Control (ESC) Module Page 10738 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 19614 Memory Seat Module X4 (AN3) Page 11932 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 5435 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: Customer Interest Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Instruments/Audio - No Speaker Audio/Warning Chimes Amplifier: All Technical Service Bulletins Instruments/Audio - No Speaker Audio/Warning Chimes Bulletin No.: 07-08-44-008 Date: April 18, 2007 TECHNICAL Subject: No Audio/No Sound Heard from Radio Speakers, Turn Signals, Hazard Signals and No Warning Chimes When a Door or Liftgate is Opened (Inspect/Seat C2 Audio Amplifier Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Speakers, Premium Audio w/Amplifier or Rear Stereo Audio (RPOs UQA, UQS or UK6) Condition Some customers may comment on one or all of the following conditions related to no audio/no sound: No sound from one or more of the radio speakers. No blinking sound heard form the turn signals or hazard signals when on. No audio warning chimes heard when a door or liftgate is opened. Cause The C2 Audio Amplifier Connector may become unseated at the amplifier. Correction Inspect/Seat the C2 Audio Amplifier Connector (16-way, Black Connector). Remove the radio, amplifier, and SIR fuses located in the Underhood Bussed Electrical Center (BEC). Gain access to the radio speaker amplifier. Refer to Radio Speaker Amplifier Replacement in SI. 4L60-E/4L65-E/4L70-E - Automatic Transmission Control Module: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (TCM) 1 - Transmission Control Module (TCM) Page 3891 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 21803 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 16692 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 22680 color of the rear inner panel (shown circled above) below the insulator (1), the insulator is the original design, which is trimmed straight across the bottom. Order a service body rear panel insulator (pictured above), referencing the parts table below. Note that the new insulator has an increased thickness and the height was extended on both ends. R & R the rear seat and any necessary trim to replace the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Further Repair for Customer Enthusiasm Only in situations when the above repairs are completed and the customer is still commenting on objectionable noise, the following additional steps can be done to sound-proof the body rear panel. This additional sound-proofing should only be done in cases deemed necessary for customer enthusiasm. Note After this procedure has been performed, the vehicle needs to be re-assembled and evaluated with the trim and rear seat fully installed in the vehicle. If the bulletin has been followed properly, the noise should be reduced to a level quieter than stock 2011 models, and no further repairs should be attempted. It has been found that controlling the wind noise at the two pressure relief valve (PRV) locations is the key to quieting the rear cab wind noise. The repair below has been found to be successful in eliminating most of the objectionable noise. 1. R & R the rear seat and any necessary trim to remove the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Note GM P/N 12378195 is not available in Canada. However several equivalents such as *Evercoat (Q-Pads) P/N 100116 and *Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. 2. Install noise and vibration sound deadening pads to backside of the body rear panel insulator. Follow the pattern shown above, ensuring they cover the two PRV locations. Use GM P/N 12378195, or equivalents commercially available through *Dynamat(R), Evercoat(R) or Dominion Sure Seal. Important Ensure that the foam tape pattern does not have any gaps in the corners and that it is securely pressed/attached to the inner rear body panel. 3. Install *Duck Brand Weatherstrip Seal (Self Adhesive Foam) P/N 1278750, or equivalent, to the inner body rear end panel following the patterns shown below: Page 2557 Page 6101 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 21441 Page 19137 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 974 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 16393 X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness (JL4) Page 12900 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 340 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Page 11288 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 22489 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 8575 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 7735 Disclaimer Page 3537 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 23069 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 4986 Specifications Idle Speed: Specifications Information not supplied by the manufacturer Page 24272 1 - Door Frame 2 - Window Switch - Left Rear (ABV) 3 - Speaker - Left Rear Door 4 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 5 - Window Motor - Left Rear (ABV) Right Rear Door (Extended Cab) Page 9200 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 2161 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 10830 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 15428 5. Install the lubricated seals. Ensure that they are fully seated. 6. Install the reservoir to the master cylinder by pressing the reservoir straight down on the master cylinder until the pin holes are aligned. 7. Carefully install the reservoir retaining pins to secure the reservoir. 8. Place the brake fluid level sensor into the reservoir, press into place to secure the sensor retaining tabs. 9. Remove the master cylinder from the vice. 10. Install the master cylinder. 11. Release the park brake. 12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). Master Cylinder Replacement (JD9, JF3, JF7) Master Cylinder Replacement (JD9, JF3, JF7) HVAC - Automatic Solar Sensor: Locations HVAC - Automatic HVAC Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 8582 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 9644 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Air Bag System - DTC B0071/B0074/B0081 Code Clearing Seat Occupant Sensor: All Technical Service Bulletins Air Bag System - DTC B0071/B0074/B0081 Code Clearing Bulletin No.: 07-09-41-004 Date: June 13, 2007 INFORMATION Subject: New Procedure for Clearing Passenger Presence System (PPS) and Sensing and Diagnostic Module (SDM) DTCs B0071, B0074, B0081 Models: 2006-2008 Buick Lucerne 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Monte Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Silverado, Suburban, Tahoe 2007-2008 GMC Yukon, Yukon Denali, Yukon XL, Yukon XL Denali A condition exists where the passenger presence system (PPS) may continue to output a fault to the sensing and diagnostic module (SDM) after the PPS has been cleared. The fault may continue to report to the SDM if the buss has not been allowed to go to sleep prior to clearing B0081 DTC in the SDM. If B0071, B0074 or B0081/0F is received, the following procedure should be followed to clear the codes. With the Ignition OFF, open and close the driver door. With a scan tool, clear PPS DTC (B0071 or B0074). While continuing to keep the doors closed, wait 60 seconds with the ignition OFF. DO NOT operate any functions in the vehicle during this time. Verify that the PPS does not have any DTCs. If PPS DTCs exist, please perform the necessary repair. With the scan tool, clear DTC B0081. Disclaimer Caster Description Alignment: Description and Operation Caster Description Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Page 11199 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 18564 Disclaimer Page 22332 Front Seat Cushion Outer Trim Panel Replacement (Power) Front Seat Cushion Outer Trim Panel Replacement (Power) Page 2147 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Page 8061 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 20212 Parking Assist Control Module: Service and Repair Object Alarm Module Replacement Page 3929 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 21195 Transmission Support Crossmember Replacement (2WD 1500/2500) Transmission Support Crossmember Replacement (2WD 1500/2500) Page 21854 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 1018 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 21621 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 17931 Note Do Not attempt to drill out the jounce bumper while attached to the strut top mount assembly. The bumper must be removed from the top mount assembly. Note Do Not attempt to drill out the jounce bumper from the lower end toward the upper end, as this could affect characteristics of the jounce bumper. 10. Enlarge the Upper ID (1) from the top side of the jounce bumper to the following dimensions: - Diameter of enlarged ID: 16 mm - Depth of enlarged ID: 15 mm 11. Ensure that the ID of the jounce bumper is as smooth as possible and free of loose material. If necessary, an Exacto knife, or equivalent, can be used to carefully trim the edge and remove any loose material. The photo above shows a jounce bumper with the enlarged upper ID (1) as compared to the original ID (2). Note Ensure that the jounce bumper is fully seated to the top mount assembly. 12. Install the jounce bumper to the top mount assembly. Ensure that the jounce bumper is secure to the top mount. 13. Assemble the coil spring and top mount to each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. 14. Install the LH and RH strut assemblies to the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 15. Move the vehicle outdoors to allow it to return to ambient temperature. 16. Test drive the vehicle under the same conditions to verify the repair. Warranty Information For vehicles repaired under warranty, use the table. Page 20414 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 10381 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 2017 Page 23353 Audible Warning Device Control Module: Diagrams Displays and Gages Connector End Views Chime Module (UL5) Page 9447 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 6035 Page 6272 Page 11281 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 11892 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 9163 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 2572 Transmission Position Switch/Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft Position Switch Replacement Page 13166 11. Tighten the left exhaust pipe nuts. Tighten the nuts to 50 N.m (37 lb ft). 12. Install the transmission crossmember. 13. Remove the support from the transmission. 14. Lower the vehicle. 15. Install the transmission oil level indicator. 16. Lock the transmission oil level indicator. 17. Install the intake manifold. Page 7842 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 2448 4. Connect the engine wiring harness electrical connector (2) to the HO2S pigtail electrical connector (1). 5. Install the CPA retainer. 6. Lower the vehicle. Page 5493 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Controls Connector End Views Engine Coolant Temperature (ECT) Sensor Page 2006 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Controls Component Viewst Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Page 22209 Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with AM7) Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with AM7) OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 8471 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 23434 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Front Door Switch Bezel Replacement Front Door Panel: Service and Repair Front Door Switch Bezel Replacement Front Door Switch Bezel Replacement Page 262 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Locations Coolant Level Sensor: Locations Cooling System Component Views Left Front of Engine Compartment (Diesel) 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Page 13906 Transmission Mount: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Transmission Mount Replacement (2WD) Page 67 For vehicles repaired under warranty, use the table. Disclaimer Page 4066 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 4062 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 12266 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 984 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 9891 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14937 Torque Converter Clutch Solenoid: Connector Views 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Page 2838 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Clutch: Customer Interest A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 14568 5. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 6. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 7. Remove the TCC solenoid bolts. 8. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 9. Reposition the harness to the side of the transmission case. 10. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 11. Remove the transmission fluid pressure switch. Page 8353 Terminator Resistor Terminator Resistor Data Communication Connector End Views Terminator Resistor Page 7600 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21891 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Page 6365 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 16411 Page 4169 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 4313 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 8904 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 17062 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 14189 25. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 26. Install the propeller shaft yoke retaining clamps and the bolts. Tighten the propeller shaft yoke retaining clamp bolts to 25 N.m (18 lb ft). 27. Install the axle shafts. 28. Fill the axle with axle lubricant. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 29. Lower the vehicle. Page 20624 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Page 1780 Vehicle Zoning Strategy Truck Zoning Page 17137 Fuse Block - I/P X4 Page 12753 Torque Converter Clutch Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 6L50/6L80/6L90 - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Page 2146 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 246 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 17712 Important: The power steering gear inlet hose cannot be routed between the brake lines and the power brake booster during installation. 1. Route the power steering gear inlet hose in the same position it was in prior to removal. 2. Install the power steering gear inlet hose (2) to the power brake booster (1) and hand tighten only. Rotate the power steering gear inlet hose clockwise until the it contacts the power brake booster housing and then hold it in position while tightening it to the fitting specification. Notice: Refer to Fastener Notice. 3. Install the power steering gear inlet hose (2) to the power steering gear. Tighten the fittings to 32 N.m (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas Without Hydroboost) Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 21537 Page 10827 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 9268 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Locations Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 16813 Warranty Information (Saab U.S. Models) Disclaimer Page 5895 Page 16015 Junction Block - Right I/P, Top View Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 17342 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (4.3L/4.8L/5.3L) Page 9920 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 7492 For vehicles repaired under warranty, use the table. Disclaimer Page 18020 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 1708 Brake Light Switch: Service and Repair Stop Lamp Switch Replacement (Non-Adjustable Pedal) Stop Lamp Switch Replacement (Non-Adjustable Pedal) Page 6856 Vehicle Zoning Strategy Truck Zoning Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 3009 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 18916 Page 19615 Memory Seat Module X5 (AN3) Fuel Hose/Pipes Replacement - Chassis (Extended Cab With 8 Ft Bed Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Extended Cab With 8 Ft Bed Fuel Hose/Pipes Replacement - Chassis (Extended Cab - w/8 Ft Bed) Removal Procedure Important: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. 3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. Page 1164 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 8952 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 14119 - The IP wiring branch to C202 may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been fully seated. Possible point of contact (2). - The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been fully seated. Possible points of contact (1, 2). - The IP wiring branch to C202 may have never been secured into place as the gray retaining clip (1) off the branch was never seated. Manual Transmission - M/T Operating Characteristics Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating Characteristics INFORMATION Bulletin No.: 03-07-29-004G Date: December 15, 2010 Subject: Manual Transmission Operating Characteristics Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle). Important Even though this bulletin attempts to cover operating characteristics of manual transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar vehicle and if possible, with similar mileage. Even though many of the conditions are described as characteristics and may not be durability issues, GM may attempt to improve specific issues for customer satisfaction. The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that repair attempts will not change. The following are explanations and examples of conditions that will generally occur in all manual transmissions. All noises will vary between transmissions due to build variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and clutch, level of insulation, etc. Basic Information Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced with clutch damper springs and dual mass flywheels. However, some speed variation will make it through to the transmission. This can create noise as the various gears will accel and decel against each other because of required clearances. Cold Operation Manual transmission operation will be affected by temperature because the transmission fluid will be thicker when cold. The thicker fluid will increase the amount of force needed to shift the transmission when cold. The likelihood of gear clash will also increase due to the greater time needed for the synchronizer assembly to perform its function. Therefore when the transmission is cold, or before it has reached operating temperature, quick, hard shifts should be avoided to prevent damage to the transmission. Gear Rattle Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a combustion knock type of noise) type noises usually occur while operating the engine at low RPMs (lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However, dual-mass flywheels do not eliminate all noise. Neutral Rattle There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with the clutch engaged, the sudden stop of the engine will create a rapid change in angular acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the components, this will create a noise. This type of noise should not be heard if the clutch is released (pedal pushed to the floor). Backlash Backlash noise is created when changing engine or driveline loading. This can occur when accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle loading, etc. and is created from the necessary clearance between all of the mating gears in the transmission, axle(s) and transfer case (if equipped). Page 14909 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 12793 Shift Solenoid: Specifications 6L50/6L80/6L90 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Shift Solenoid Valve State and Gear Ratio Page 22957 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Diagrams Pedal Positioning Switch: Diagrams Adjustable Pedal Connector End Views I/P Multifunction Switch Assembly Page 1137 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 14176 5. Place an alignment mark between the pinion and the pinion yoke. 6. Install the J 8614-01 as shown. 7. While holding the J 8614-01, loosen the pinion nut. 8. Remove the washer. 9. Remove the pinion nut and washer. 10. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. Page 14852 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 3262 11 - Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) 12 - Seat Adjuster Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Page 19915 Page 8247 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Campaign - BCM Reprogramming for Battery Drain Body Control Module: Recalls Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 11536 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 21574 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch Page 6721 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 15909 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 1331 Object Sensor - Right Rear Corner Object Sensor - Right Rear Middle Page 5015 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 6890 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 5932 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 8636 Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice Excessive Force and Oxygen Sensor Notice Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Page 18757 Air Bag Deactivation Switch: Diagrams Inflatable Restraint I/P Module Disable Switch (C99) Page 21038 Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Extended Cab) Rear Side Door Window Regulator Motor Replacement (Extended Cab) Page 4898 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 5801 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 2962 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 16717 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 13199 Fluid - A/T: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement Steering/Suspension - Ball Joint Availability Ball Joint: Technical Service Bulletins Steering/Suspension - Ball Joint Availability INFORMATION Bulletin No.: 07-03-08-009B Date: December 07, 2009 Subject: Two New Service Ball Joint Kits Available for Aluminum and Cast Iron Lower Control Arms - Kits NOT Interchangeable Models: 2007-2010 Cadillac Escalade, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Tahoe (1500 Series) 2007-2010 GMC Sierra, Yukon (1500 Series) Supercede: This bulletin is being revised to add the Silverado and Sierra models and update service information. Please discard Corporate Bulletin Number 07-03-08-009A (Section 03 Suspension). For the 2007-2010 model years, 1500 series light duty utility vehicles were built concurrently with either aluminum or cast iron front lower control arms. Each type of lower control arm requires a unique ball stud service part. Important Complete lower control arms should not be replaced for lower ball joint failures. All lower ball joints are now serviceable on aluminum and cast iron control arms for 1500 series pickup and utility models. The kit for cast iron control arms lower ball joints is P/N 19209396 and the aluminum lower ball joint kit is P/N 19256481. These kits are NOT interchangeable. There are new special tools that are released to service the lower ball joints on-vehicle (J-41805 and CH-49240). For the new lower ball joint service procedures, refer to Lower Control Arm Ball Joint Replacement in SI. Parts Information Disclaimer Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 16428 X305 Body Harness to Passenger Seat Harness (-AN3) Page 10985 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 14077 6. Remove the 2 detent spring bolts (3). Remove the detent spring assembly (2). 7. Disconnect the internal wiring harness from the detent lever/IMS assembly. Important: As the control valve assembly is removed, be careful not to lose the manual selector valve pin or allow the manual selector valve to slide out of the control valve assembly. 8. Remove 10 bolts at locations marked (1) and 4 bolts at locations marked (2). Support the control valve assembly, about 10 pounds, and remove the last bolt marked (1). Page 15211 Rear Brake Caliper Replacement (JH6, JH7) Rear Brake Caliper Replacement (JH6, JH7) Page 10325 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Page 16939 View of the connector when released from the component. View of another type of Micro 64 connector. Page 8641 Tighten the sensor to 42 N.m (31 lb ft). 3. If vehicle is a 4WD perform the following steps otherwise proceed to step 7. 4. Install the HO2S pigtail electrical connector clip (9) to the fuel line bracket. 5. Connect the engine wiring harness electrical connector (7) to the HO2S pigtail electrical connector (8). 6. Connect the CPA retainer. 7. If vehicle is a 2WD perform the following steps, connect the HO2S pigtail electrical connector (7) to the engine wiring harness electrical connector (6). 8. Connect the CPA retainer. 9. Lower the vehicle. Page 19492 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Page 16819 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12714 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 2106 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 11416 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 1474 Disclaimer Page 18346 Control Assembly: Locations HVAC Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 14752 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 11709 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 23629 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 12158 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 423 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 11743 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 11535 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 8234 1 - Rear Bumper 2 - Junction Block - Rear Lamps 3 - Terminator Resistor 4 - Trailer Connector (UY7) Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Page 10975 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 23936 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 22565 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Locations Power Window Switch: Locations Window Systems Component Views Passenger Door 1 - Outside Rearview Mirror - Passenger 2 - Door Lock Switch - Passenger (AU3 -AN3/DL3) 3 Passenger Door Switch (PDS) (AN3/DL3) 4 - Door Latch Assembly - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) 6 - Speaker - Right Front 7 - Window Motor - Passenger (A31) 8 - Window Switch - Passenger (A31 -AN3/DL3) 9 - Heated Seat Switch Passenger (AN3) Left Rear Door (Crew Cab) Page 2367 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 8988 Page 5066 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 11534 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 2583 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Page 19389 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 1876 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 1999 Camshaft Position Sensor: Connector Views Engine Controls Connector End Views Camshaft Position (CMP) Sensor Page 12052 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 11490 5. Remove the engine wiring harness connector position assurance (CPA) retainer at the fuel meter body. 6. Disconnect the engine wiring harness electrical connector (1) from the fuel meter body. 7. Remove the engine wiring harness clips (1, 2) from the engine harness brackets. Page 17409 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Important: * Always note the orientation of the relay. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Page 22197 Front Seat Back Cushion Cover and Cushion Pad Replacement Front Seat Back Cushion Cover and Cushion Pad Replacement Page 4049 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Locations Power Window Switch: Locations Window Systems Component Views Passenger Door 1 - Outside Rearview Mirror - Passenger 2 - Door Lock Switch - Passenger (AU3 -AN3/DL3) 3 Passenger Door Switch (PDS) (AN3/DL3) 4 - Door Latch Assembly - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) 6 - Speaker - Right Front 7 - Window Motor - Passenger (A31) 8 - Window Switch - Passenger (A31 -AN3/DL3) 9 - Heated Seat Switch Passenger (AN3) Left Rear Door (Crew Cab) Page 7964 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 6234 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 10297 Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures Fuel System Cleaning See: Service and Repair Page 10681 4. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 N.m (80 lb in). 5. Install the fuel/EVAP line clip nut (2). Tighten the nut to 20 N.m (15 lb ft). 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. 9. If equipped with 2WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle. 10. Install the fuel/EVAP line bracket locator tab to the frame. 11. Install the fuel/EVAP line clips to the frame and crossmember. 12. Install the fuel/EVAP line bracket bolt (2). Tighten the bolt to 9 N.m (80 lb in). 13. Install the fuel/EVAP line clip nut (1). Tighten the nut to 20 N.m (15 lb ft). 14. Remove the caps from the fuel and EVAP lines. 15. Connect the fuel tank EVAP line quick connect fitting to the chassis line. 16. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Electrical - No Start/No Crank/Int Electrical Operations Wiring Harness: Customer Interest Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Page 12696 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2377 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Service and Repair Condenser HVAC: Service and Repair Condenser Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the fascia. 3. Remove radiator support bolts (1). Access the bolts from the rear of the upper radiator support. Refer to Radiator Support Replacement. 4. Remove radiator support bracket bolts (1). 5. Remove the compressor discharge hose assembly bolt from the condenser. 6. Disconnect the compressor discharge hose assembly from the condenser. Page 24737 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 21581 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 16219 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 1258 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 21546 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 3442 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 11716 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 7377 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 4908 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 23441 Important: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 3. Mount the tire to the rim. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 5556 6. Install the flex coupling (1). Expand the sleeves of the flex coupler, if necessary, to properly fit over each pipe end. The centerline of the installed flex coupling should run parallel to the straight section of pipe (no bends in the coupling) for optimum performance. 7. Install the U-bolt clamps (2) on each sleeve end of the flex coupling. Tighten Tighten the U-bolt clamps to 30 Nm (22 lb ft). 8. Lower the vehicle. 9. Verify that the condition has been fixed. 1999-2000 4WD Models Built Prior to 1/20/2000 and All 2000-2011 2WD and 4WD Models Built After 1/2000 (With Regular Cab Short Bed ) Note This procedure uses a locally obtained 76 mm (3 in) flex coupling. Most larger exhaust shops will have these available. The kit listed below (P/N 15076990) is too long to use on regular cab short bed vehicles. Do not order the parts listed below. These models require the installation of a flex coupling. The flex coupling has adapter sleeves for the installation of U-bolt clamps. This procedure uses the U-bolt clamps, but the preferred installation method is to weld the flex coupler to the exhaust pipe. 1. Raise the vehicle. 2. Locate the first available straight section of pipe rearward of the mid-joint flange and forward of the muffler assembly. 3. Measure approximately 76 mm (3 in) on the straight pipe and mark. 4. Using a suitable cutting tool, cut out the marked section of the pipe and remove. 5. Remove any burrs, if necessary, before installing the flex coupler pipe. 6. Install the flex coupling, follow the manufacturer's installation instructions (1). Expand the sleeves of the flex coupler, if necessary, to properly fit over each pipe end. The centerline of the installed flex coupling should run parallel to the straight section of pipe (no bends in the coupling) for optimum performance. 7. Lower the vehicle. 8. Verify that the condition has been fixed. 1999-2000 2WD Models Built Prior to 1/2000 These models will require the installation of a flex coupler, two Y-pipe support brace rods w/integral U-bolt clamp assemblies on the LH and RH sides of the transmission rear mount and new transmission mount studs and nuts. The Y-pipe support braces are used in combination with the flex coupler to reduce exhaust moan. 1. Install the flex coupler using steps 1-7 in the first procedure(s). 2. Support the transmission with a suitable adjustable jack stand. 3. Remove the two bolts and nuts from the transmission rear mount. 4. Position the transmission rear mount and install two new studs to the mount. 5. Install the new studs supplied with the kit to the transmission mount. Locations Shift Interlock Solenoid: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 24661 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 14769 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 9579 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 23383 Page 14958 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 9600 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 2551 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 4209 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 8573 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Electrical - Various Rear Door Electrical Malfunctions Wiring Harness: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 3340 Notice: Refer to Fastener Notice. 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 N.m (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 450 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 17622 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Page 13625 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Page 11413 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23193 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 23606 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 3434 1 - Window Switch - Right Rear (ABV) 2 - Window Motor - Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 4 - Speaker - Right Rear Door Page 18429 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 11720 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Bleeding Important: * Use clean, new power steering fluid type only. See the Maintenance and Lubrication subsection for fluid specifications. Refer to Fluid and Lubricant Recommendations. * Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not touch any other part of the vehicle. * Loose connections may not leak, but could allow air into the steering system. Verify that all hose connections are tight. Important: Power steering fluid level must be maintained throughout bleed procedure. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark on cap stick fluid level indicator. Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will discharge the hydro-boost accumulator. 1. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following procedure: 1. Start the engine. 2. Firmly apply the brake pedal 10-15 times. 3. Turn the engine OFF. 2. Raise the vehicle until the front wheels are off the ground. Refer to Vehicle Lifting. 3. Key on engine OFF, turn the steering wheel from stop to stop 12 times. Vehicles equipped with hydro-boost systems or longer length power steering hoses may require turns up to 15 to 20 stop to stops. 4. Verify power steering fluid level per operating specification. Refer to Checking and Adding Power Steering Fluid (With Hydroboost) Checking and Adding Power Steering Fluid (Without Hydroboost). 5. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid aeration (pump noise/whining). 6. Verify the fluid level. Repeat the bleed procedure, if necessary. Page 8553 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 1425 11 - Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) 12 - Seat Adjuster Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor Passenger (AN3) Page 16361 Disclaimer Page 17344 X116 Inline Harness Connector End Views X116 Battery Positive Harness to Brake Clutch Harness (9L4) 4L60-E/4L65-E/4L70-E - Automatic Transmission Torque Converter Cover: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Torque Converter Cover Replacement Page 24193 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 4993 Radiator Cooling Fan Motor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 5809 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 5941 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 24230 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 21896 Door Module: Electrical Diagrams Door Control Module Schematics Power, Ground and Serial Data Interior - Front Power Seat Adjust/Memory Inoperative Power Seat Switch: All Technical Service Bulletins Interior - Front Power Seat Adjust/Memory Inoperative Bulletin No.: 06-08-50-012 Date: October 06, 2006 TECHNICAL Subject: Front Driver or Passenger Power Seat Adjust Functions Inoperative and/or Driver Seat Memory Inoperative (Check Power Seat Switch Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (New Style), Suburban, Tahoe 2007 GMC Sierra (New Style), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the front driver or passenger power seat adjust functions are inoperative. They may also comment that the driver seat memory is inoperative. Cause The cause of this condition may be due to the power seat switch connector not being fully seated. Correction Remove the front seat cushion outer trim panel following the replacement procedure in SI. Verify that the power seat switch connector is fully seated. Reseat the connector and test the seat functions. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15489 10. Remove the park brake lever mounting nuts. 11. Position the floor carpet to expose the park brake cable pass-through grommet. 12. Release the park brake cable pass-through grommet from the vehicle floor. 13. Remove the park brake lever and front cable from the vehicle. Installation Procedure Important: Ensure the grommet for the front park brake cable is properly seated in the front floor panel. 1. Insert the front brake cable through the hole in the front floor panel and seat the pass-through grommet. 2. Position the floor carpet to the floor pan. Page 9115 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 3874 Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Label Page 11037 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 12199 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 15420 Page 6225 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 198 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 11213 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 15496 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the negative battery cable. 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 6329 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 23055 Page 5947 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 20038 A/T Shift Lock Control Solenoid Speaker - Left Front (UQA) Speaker - Left Front Tweeter Page 8945 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 17127 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 18335 The concern must be current before diagnosis can be performed. Review and print the following SI documents - Electrical Center Identification Views, for use during diagnosis: - Junction Block - Right I/P, Top View - Junction Block - Right I/P X4 - Junction Block - Right I/P X5 Locate the Junction Block - Right Side IP on the vehicle. For the appropriate actuator, measure the following signals for voltage/resistance from the BACK of the X4 or X5 connector and record the following: DO NOT unplug the X4/X5 connector. Turn Ignition On, A/C Blower Full, if possible - mode on "panel" and Temp to "cold." Once the fault is removed, the actuator will stay in default position until commanded to a new position. Change commanded position regularly to see if the issue is still current. Continue to monitor door positions (feedback) on Tech2 to see if it changes during circuit testing. - Ignition Voltage - 12V - Door Control Signal - 2.5V when stationary, OV when commanded toward "cold" or "panel", 5V when commanded toward "hot" or "defrost" - Low Reference - less than 40 ohm with ignition on. Less than 10 ohm with ignition off - Door Position Signal - measure voltage - 5 Volt Reference - 5V If any signals do not display the correct value or if the issue is corrected during testing, pull the connector and check the terminal for poor tension (use the appropriate terminal tool). Replace or repair the terminal if poor tension is found. If all signals are correct at RH BEC, reconfirm the customer's comments. If the condition is not present, no further repairs are necessary. If the condition is still present, recheck the actuator connector 5 volt reference circuit, pin drag test and repair connector/pin as necessary. Warranty Information For vehicles repaired under Enqineerinq direction, use the table. Page 3639 4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 5. Install the air cleaner outlet resonator to the MAT/IAT sensor. 6. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). Page 11099 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 7018 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 7353 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 10437 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 16030 Page 23917 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 7304 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Reluctor Ring Replacement Crankshaft Position Sensor Reluctor Ring Replacement Tools Required j 5590 Rear Pinion Bearing Race Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position (CKP) sensor reluctor ring. Installation Procedure Page 11045 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 7026 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Pressure Regulator Replacement Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Page 8212 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 22589 Driver Door Switch (DDS) X1 (AN3/DL3) Driver Door Switch (DDS) X2 (AN3/DL3) Page 3075 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 6442 Page 16215 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 21817 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 13525 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 14882 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2942 Page 11433 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 5319 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 9010 * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Page 11648 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 14879 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 8256 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 5225 6. Install the air cleaner outlet duct. 7. Tighten the air cleaner outlet duct clamp at the throttle body. Tighten the clamp to 4 N.m (35 lb in). 8. Tighten the air cleaner outlet duct clamp at the mass airflow sensor(2). Tighten the clamp to 4 N.m (35 lb in). Page 24367 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2906 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 3120 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 23892 View of the connector when released from the component. View of another type of Micro 64 connector. Page 9456 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 7031 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11995 5. Remove the knock sensor bolt and sensor. Installation Procedure Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). Page 3338 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Connect the internal wiring harness electrical connectors to the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) 23. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 24. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 5059 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 795 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 23556 Courtesy Lamp: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 21196 Page 4042 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 3061 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 7049 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 24508 6. Cut the five-wire connector from the windshield washer solvent heater assembly. Vary the length of the five wires on the connector. 7. Discard the windshield washer solvent heater assembly and, if install in recall 08048, the jumper harness with inline fuse. 8. Wrap the large connector with two wires in electrical tape. 9. Wrap the red and green wires on the small connector separately. 10. Wrap the five wires on the small connector with electrical tape. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 3079 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 11764 Crankshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 9353 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 17279 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 14950 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 7398 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 22882 Disclaimer Page 13581 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Seat Belt Height Adjuster Knob Replacement - Front Seat Belt Height Adjuster: Service and Repair Seat Belt Height Adjuster Knob Replacement - Front Seat Belt Height Adjuster Knob Replacement - Front Page 18825 Disclaimer Page 16754 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 10976 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 23494 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Page 4883 Radiator Cooling Fan Control Module: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 5004 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 8603 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6108 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 24648 Engine Controls - Cruise Control Turns Off When Operated PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Locations Turn Signal Switch: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 5159 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 15263 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Page 19417 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 1105 View of the connector when released from the component. View of another type of Micro 64 connector. Page 4282 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 16970 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 12102 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 3885 Vehicle Zoning Strategy Truck Zoning Page 13533 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 5230 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 426 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 11688 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 23027 Page 10426 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 7499 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 24167 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21979 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab Existing Motor) Perform the Initialization/Teach Procedure any time a new sunroof motor/actuator is installed in the vehicle. 1. Press and hold the open switch until the full open position. 2. Release the switch. 3. Press and hold the open switch for 10 seconds or more. The glass panel will move further rearward of the open position, stall at the hard stop, and move back slightly to the soft stop or full open position. 4. Release the switch 5. Press and hold the open switch within 6 seconds. 6. Hold the open switch until the glass panel moves to the closed position and stops. 7. Release the switch. Page 24624 Wiper Blade: Removal and Replacement Windshield Wiper Blade Replacement Page 4977 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 7813 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If vehicle is a 2-wheel drive (2WD) perform the following steps, otherwise proceed to step 5. 3. Disconnect the connector position assurance (CPA) retainer. 4. Disconnect the HO2S pigtail electrical connector (7) from the engine wiring harness electrical connector (6). 5. If vehicle is a 4-wheel drive (4WD) perform the following steps, disconnect the CPA retainer. 6. Disconnect the engine wiring harness electrical connector (7) from the HO2S pigtail electrical connector (8). Page 2941 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch Page 7 Alarm Module: Diagrams Immobilizer Connector End Views Theft Deterrent Control Module Page 16496 X700 - X799 Inline Harness Connector End Views X700 Left Rear Door Harness to Body Harness (Extended Cab) Page 13524 Vehicle Zoning Strategy Truck Zoning Page 15398 Page 2688 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 4155 Fuse Block - Underhood X5 Restraints - Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6876 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 22610 For vehicles repaired under warranty, use the table. Disclaimer Page 9423 Intake Air Temperature Sensor: Diagrams Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 24482 Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Lens Replacement Windshield Outside Moisture Sensor Lens Replacement Page 24682 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 11239 Page 4061 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 16290 Junction Block - Rear Lamps X2 Page 12150 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 17984 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 16705 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 24703 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 21850 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3621 1. Install the air cleaner outlet resonator to the MAF/IAT sensor and throttle body. Notice: Refer to Fastener Notice. 2. Tighten the air cleaner outlet resonator clamp (2) at the throttle body. Tighten the clamp to 4 N.m (35 lb in). 3. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). 4. Connect the PCV hose (1) to the air cleaner outlet resonator. Page 264 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 16110 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 477 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Remove the knock sensor heat shield bolt and shield. Page 21381 Front Floor Panel Carpet Replacement (Regular Cab) Front Floor Panel Carpet Replacement (Regular Cab) Page 6443 Page 22331 Page 269 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Specifications Compression Check: Specifications No cylinder should read less than .............................................................................................................................................................. 690 kpa (100 psi) Page 17580 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Wheel Alignment Specifications (Part 1) Page 7930 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 4044 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 8093 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 2724 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Heated Oxygen and Oxygen Sensor Notice Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice Heated Oxygen and Oxygen Sensor Notice Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Page 4658 17. Install the starter. 18. Connect the oil level sensor electrical connector (7). 19. Install the engine harness bracket bolts. Tighten the bolts to 12 N.m (106 lb in). Page 7806 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Service and Repair Balance Shaft Bearing: Service and Repair Balance Shaft Bearing and/or Bushing Replacement Tools Required * J 26941 Bushing and Bearing Remover * J 38834 Balance Shaft Service Kit Removal Procedure Important: The balance shaft and the front bearing are serviced only as a package. Do not remove the bearing from the balance shaft. 1. Remove the balance shaft. 2. Using J 26941 and the J 38834, remove the balance shaft rear bearing. 1. Install the J 26941 legs behind the balance shaft rear bearing and secure. 2. Install the J 38834-1 with the short threaded end through the balance shaft bore in the front of the engine block. 3. Install J 38834-1 into the J 26941. 4. Slide the J 38834-2 onto the J 38834-1 and into the balance shaft bore of the engine block. 5. Install the J 38834 bearing, washer, and nut onto the J 38834-1. 6. Using a wrench, secure the J 38834-1, and then rotate the J 38834 nut clockwise until the balance shaft rear bearing is removed from the engine block. 7. Remove the J 26941 from the balance shaft rear bearing. 3. Discard the balance shaft rear bearing. Installation Procedure 1. Using J 38834, install the balance shaft rear bearing. 1. Install the J 38834-3 onto the short threaded end of the J 38834-1. 2. Install the J 38834 nut, the washer, and the bearing on the long threaded end of the J 38834-1. 3. Install the J 38834-2 onto the J 38834-1 so that the smaller diameter of the J 38834-2 will be facing the front of the engine block. 4. Install the J 38834-2 on the inside of the balance shaft front bearing bore. 5. Lubricate the NEW balance shaft rear bearing with clean engine oil. 6. Install the balance shaft rear bearing onto the J 38834-2. 7. Align the balance shaft rear bearing for installation. 8. Using a wrench, secure the J 38834-1 into place. 9. Rotate the J 38834 nut until the balance shaft rear bearing is properly and completely pushed into the balance shaft rear bearing bore. Page 24306 1 - Window Switch - Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 3 - Door Latch Assembly - Right Rear 4 - Speaker - Right Rear Door 5 - Window Motor Right Rear (A31) Left Rear Door (Extended Cab) Page 6181 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 11699 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 4554 Disclaimer Page 14460 2. Assemble 1 bearing cup part way into 1 side of the yoke. 3. Turn the yoke ear toward the bottom. 4. Assemble the cross into the yoke so the trunnion seats freely into the bearing cup. 5. With the trunnion seated in the bearing cup, press the bearing cup into the yoke until the bearing cup is flush with the yoke ear. 6. Assemble the opposite bearing cup part way into the yoke ear. 7. Ensure that the trunnions start straight and true into both bearing cups. 8. Press the opposite bearing cup into the yoke ear while working the cross all the time in order to inspect for a free unbinding movement of the trunnions in the bearing cups. Important: If there seems to be a hang-up or binding, stop pressing, and inspect the needle bearings for misalignment in the bearing cup. 9. Press the bearing cup into the yoke until the bearing retainer groove clears the inside of the yoke. 10. Assemble the bearing retainer in the retainer groove. 11. Continue pressing until you can snap both retainers into place. Lighting - Brake Lamps Turn Off After Stop/Pedal Applied Brake Light Switch: Customer Interest Lighting - Brake Lamps Turn Off After Stop/Pedal Applied TECHNICAL Bulletin No.: 08-08-42-003A Date: August 14, 2009 Subject: Stop Lamps Intermittently Turn Off After Coming to a Complete Stop While Still Having Pressure on Brake Pedal (Replace Stop Lamp Switch) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to provide a new part number. Please discard Corporate Bulletin Number 08-08-42-003 (Section 08 - Body & Accessories). Condition Some customers may comment on the stop lamps turning off prior to the brake pedal reaching the fully released position. Some customers may also comment on the stop lamps turning off while having light pressure on the brake pedal. Some customers with Integrated Trailer Brake Control (ITBC) may comment that the electronic trailer brakes disengage after the vehicle has come to a complete stop. This disengaging of the trailer brakes coincides with the stop lamps turning off. Cause This condition may be caused by not enough pressure being applied to the stop lamp switch to keep the brake lights on. Correction Technicians are to replace the stop lamp switch. The new stop lamp switch has a reduced internal spring apply force, which will allow the lamps to stay on with less applied brake force. 1. Refer to SI for Stop Lamp Switch replacement procedures. 2. Use the new Stop Lamp Switch, P/N 25981009. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 10868 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 7926 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 2907 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 4332 Disclaimer Page 24654 Vehicle Zoning Strategy Truck Zoning Page 4094 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 17840 Control Arm: Service and Repair Lower Control Arm Replacement Lower Control Arm Replacement (1500) Special Tools * J 43631 Ball Joint Separator * J 45851 Ball Joint Separator Protector Adapters Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the stabilizer shaft link from the lower control arm. 4. Remove the wheel drive shaft, if equipped. 5. Using mechanics wire or equivalent, support the knuckle assembly and upper control arm. 6. Remove the lower ball joint retaining nut. Page 8911 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 13068 For vehicles repaired under warranty, use the table. Disclaimer Page 4683 16. Remove the engine wiring harness ground nut and ground wire (1) from the rear of the right cylinder head. 17. Remove the stud (1) holding the engine wiring harness bracket. 18. Reposition the engine wiring harness with the bracket aside. Page 15781 1 - Turbocharger Vane Position Control Solenoid Valve 2 - Glow Plug Control Module (GPCM) 3 Fuel Rail Temperature (FRT) Sensor 4 - Intake Air Temperature (IAT) Sensor 2 Connector 5 X128 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 - Generator - Left (K76) 8 - A/C Compressor Clutch (C67/CJ2) 9 - Engine Coolant Temperature (ECT) Sensor 1 10 - Engine Coolant Temperature (ECT) Sensor 2 11 - Camshaft Position (CMP) Sensor 12 - X127 13 Generator - Right 14 - Manifold Absolute Pressure (MAP) Sensor 15 - Intake Air Heater (IAH) Module 16 - Intake Air Temperature (IAT) Sensor 2 17 - Fuel Heater 18 - A/C Low Pressure Switch (C67/CJ2) Front of the Engine (Gas - 4.3L) Page 18385 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8362 Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagrams can be found via their numbers at Vehicle Locations See: Locations OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 7364 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 24740 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 4246 Tire Pressure Sensor: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 2926 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 1917 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 6072 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 2091 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 22118 Memory Seat Module X7 (AN3) Page 6723 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Electrical - Various Electrical System Malfunctions Wiring Harness: Customer Interest Electrical - Various Electrical System Malfunctions Bulletin No.: 06-08-45-009 Date: October 31, 2006 TECHNICAL Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on one or all of the following conditions: Rear door locks inoperative Rear windows inoperative Door courtesy lamps inoperative or stay on at times Rear speakers inoperative Any fuse (related to the rear doors) that is blown/shorted SIR codes related to the pretensioner Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction This repair operation is intended to be done on both B-pillars. Remove the lower B-pillar cover. Disconnect the Supplemental Inflatable Restraint (SIR) connector. Inspect the wiring harness in the B-pillar around the seat belt retractor. Make any necessary wiring harness repairs. Wrap the "entire" harness with electrical tape. Install conduit tubing around the harness. Page 24154 Vanity Lamp: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 7070 Electrical - Various Rear Door Electrical Malfunctions Wiring Harness: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 5395 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 6152 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 5154 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Fuse Block - I/P, Top View Power Door Lock Relay: Locations Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Label Page 5979 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Service and Repair Shackle: Service and Repair Spring Shackle Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the leaf spring assembly from vehicle. 3. Remove the shackle nut and the bolt from the spring. Installation Procedure 1. Install the shackle to the spring. Notice: Refer to Fastener Notice. 2. Install the shackle nut and bolt to the spring. Tighten the shackle nuts to 95 N.m (70 lb ft). 3. Install the leaf spring assembly to the vehicle. 4. Remove the safety stands. 5. Lower the vehicle. Page 11297 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Electrical - Various Rear Door Electrical Malfunctions Wiring Harness: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 8126 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14756 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 14461 12. If seating the retainer is difficult, spring the yoke slightly with a firm blow from a dead blow hammer. 13. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so the snap ring seats in the bearing cup groove. Page 9731 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 8118 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 16914 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 15229 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered, non-lubricated compressed air. Assembly Procedure Important: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure the square-cut piston seal is not twisted. Steering Linkage Inner Tie Rod Replacement Tie Rod: Service and Repair Steering Linkage Inner Tie Rod Replacement Steering Linkage Inner Tie Rod Replacement Removal Procedure Important: After removing the boot, inspect the inner tie rod for evidence of corrosion or contamination. If none is evident, continue with the repair. If corrosion or contamination is evident, replace the steering gear. 1. Remove the steering gear boot. Notice: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear. Notice: The pipe wrench must be placed at the valve end of the steering gear and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear. 2. Place a pipe wrench on the steering gear rack (1) next to the steering linkage inner tie rod housing (2). 3. Place a wrench on the flats of the steering linkage inner tie rod housing (2). 4. Rotate the steering linkage inner tie rod housing (2) counterclockwise, while holding the steering gear rack stationary, until the steering linkage inner tie rod separates from the steering gear rack (1). Installation Procedure Important: All threads must be clean prior to LOCTITE(R) application. Check the LOCTITE(R), or equivalent, container for the expiration date. Use only enough LOCTITE(R) to evenly coat the threads. 1. Apply LOCTITE(R) 262, or equivalent, to the steering gear inner tie rod threads. 2. Attach the steering linkage inner tie rod onto the steering gear rack. Notice: Refer to Pipe Wrench Positioning Notice. Page 6208 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 8012 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Reluctor Ring Replacement Crankshaft Position Sensor Reluctor Ring Replacement Tools Required j 5590 Rear Pinion Bearing Race Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position (CKP) sensor reluctor ring. Installation Procedure Page 13772 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 4531 5. Using the J 42073, install the valve stem oil seal onto the valve guide. 1. Tap the valve stem oil seal onto the valve guide until the J 42073 bottoms against the valve spring seat. 2. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed against the valve guide. There should be a 1-2 mm (0.03937-0.07874 in) gap between the bottom edge of the valve stem oil seal and the valve guide. 6. Install the valve spring (3). 7. Install the valve spring cap (2) onto the valve spring (3), over the valve stem. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 8. Use the J 5892-D in order to compress the valve spring. Hook the slotted end of J 5892-D under the washer on the valve rocker arm bolt. 9. Apply steady pressure on the valve spring cap until the valve keys are accessible. Page 11241 Page 14102 4. Release the wiring harness conduit from the retainers that secure it to the rear of the engine and at the top of the transmission bell housing. Note The engine intake manifold is shown removed to provide clarity. 5. Pull the wiring harness up gently at the rear of the engine (1) and inspect the wiring harness for chafed/shorted wiring (2). If chafing is not observed on exposed wiring then extract the wiring from the protective conduit and inspect ALL areas for chafing. ‹› If chafing (1) or damage is found, repair the wiring. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the wiring harness by covering the sharp edge with butyl tape or a suitable material. Secure the wiring harness conduit as needed. 7. Install the upper intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement in SI. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Chassis Body Mounts Left Side Frame Rail 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. Page 8984 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 8090 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 20322 Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 6. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 7. Replace the fuse(s) in the fuse panel when finished towing. Tracker Models Note: Locking the steering column when towing your vehicle may damage the steering column. Always unlock the steering column before towing. Important: ^ Two-wheel drive Trackers cannot be dinghy towed. Two-wheel drive models MUST be towed with the rear drive wheels on a dolly. ^ The towing speed must not exceed 90 km/h (55 mph). In order to properly dinghy tow a 4WD Tracker, follow these steps: 1. Set the parking brake. 2. Shift the transmission into Park (AT) or second gear (MT). 3. With the ignition key in the ON position, move the transfer case to Neutral. Make sure the 4WD indicator on the instrument panel cluster is Off. 4. Turn the ignition key to ACC in order to unlock the steering wheel. 5. Release the parking brake. Stop towing the vehicle every 300 km (200 mi) and do the following steps: 1. Start the engine of the towed vehicle. 2. Leave the transfer case shift lever in Neutral. 3. Shift the transmission to Drive (AT). For vehicles with (MT), leave the transmission in second gear with the clutch engaged. 4. Run the engine at medium speed for one minute to circulate the oil through the transfer case. 2003-2007 Pontiac Vibe Only the front wheel drive vehicles with manual transmission are designed to be dinghy towed. Use the following procedure to properly dinghy tow these models: 1. Place the shift lever in Neutral. 2. Turn the ignition switch to the ACC position to avoid locking the steering wheel. Make sure that the audio system is turned off and that nothing is plugged into the power outlets. 3. Release the parking brake. 4. After dinghy towing the vehicle, let the engine idle for more than three minutes before driving the vehicle. Four Wheel Drive and All Wheel Drive Light Duty Trucks Page 1010 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 20627 handle between the pawl and the tower where the gray pin enters through the spring and the pawl. 3. Cycle the handle at least 20 times to work the grease around the pin and to make sure that the squeak has been eliminated. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8591 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 23924 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 6166 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 14412 6. Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 7. Road test the vehicle and verify that the noise is gone. Note Do Not replace the slip yoke unless the cleaning and lubrication procedure is ineffective. 8. If the vehicle has a repeat concern after lubricating the slip yoke splines, it may be necessary to replace the propeller shaft slip yoke with a new nickel-plated slip yoke. Replace the Propeller Shaft Slip Yoke 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. Important Some U-joints are fastened with nylon injection clips. If so, Do Not reuse the U-joint. Replace with GM P/N 12479126 U-Joint kit. 2. Replace the propeller shaft slip yoke with a new nickel-plated slip yoke. Refer to Propeller Shaft Slip Yoke Replacement in SI. 3. Install the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2380 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Lighting - Turn Signals Have Increased Flash Rate Body Control Module: All Technical Service Bulletins Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13021 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 18753 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Page 9106 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 16506 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 5982 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 7106 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 4415 Dinghy towing is permitted on the trucks shown with the transfer case placed in the Neutral position. Refer to the end of this bulletin for identification information to determine type of transfer case. The vehicles shown should NOT be dinghy towed because the transfer cases in these vehicles either have no neutral position or do not have an internal oil pump to provide lubrication while being towed. In order to properly tow the vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when towing with all four tires on the ground is unavoidable, both the front and the rear propeller shafts must be removed in order to prevent damage to the transfer case and/or transmission. Because front and rear propeller shafts are matched to attaching components at assembly, refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Towing Procedure In order to properly dinghy tow the vehicle, use the following procedure: 1. Firmly set the parking brake. Page 10289 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Page 9403 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 6389 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 23490 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 6840 Accelerator Pedal Position Sensor: Diagrams Engine Controls Connector End Views Accelerator Pedal Position (APP) Sensor Page 21502 Page 11516 Page 2320 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 23937 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 17821 Tie Rod: Service and Repair Steering Linkage (Non-Rack & Pinion) Steering Linkage Inner Tie Rod Replacement Tools Required J 34028 Inner Tie Rod Wrench Removal Procedure 1. Remove the engine shield, if equipped. 2. Remove the steering linkage outer tie rod. 3. Remove the steering linkage inner tie rod (1) from the relay rod using wrench J 34028 (2). Installation Procedure 1. Remove all traces of oil, grease, or other contaminants. 2. Clean the threads of the steering linkage inner tie rod with denatured alcohol or the equivalent and allow to dry. 3. Apply red LOCTITE(TM) threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the steering linkage inner tie rod. Notice: Refer to Fastener Notice. 4. Install the steering linkage inner tie rod (1) to the relay rod using wrench J 34028 (2). Tighten the steering linkage inner tie rod to 100 N.m (74 lb ft). 5. Install the steering linkage outer tie rod. 6. Install the engine shield, if equipped. 7. Adjust the front toe. Page 9491 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 16479 Page 12952 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13086 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 17267 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 19762 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Page 16399 X126 Inline Harness Connector End Views X126 Instrument Panel Harness to Chassis Harness (-JL4) Page 6100 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 16492 X500 Inline Harness Connector End Views X500 Left Front Door Harness to Body Harness (YE9 -AN3/DL3) X501 Page 14691 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Disable the SIR system. 2. Remove the knee bolster. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. Page 2513 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21800 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 23621 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 12344 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). Tighten the bolts to 10 N.m (89 lb in). Ball Check Valves 5. Install the 7 checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Page 10649 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 12. If equipped with 2-wheel drive (2WD) perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service. 13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (2). 16. Remove the fuel/EVAP line clip nut (1). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Page 19982 Visually inspect and pull on the C2 Audio Amplifier Connector (1). If the connector is properly seated, then refer to SI for further diagnosis based on the customers condition. If the connector is loose, then reinstall the C2 Audio Amplifier Connector. Verify the connector is seated and locked into place. Install the fuses. Verify the condition has been fixed and clear any DTCs. If securing the connector does not correct the condition, refer to SI for further diagnosis and repair. Install the radio speaker amplifier assembly and any other components removed to gain access to the amplifier. Refer to Radio Speaker Amplifier Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 23897 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 11904 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 7933 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 17645 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 12304 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 5514 9. Remove the left rear CPA retainer. 10. Disconnect the engine wiring harness electrical connector (1) from the left rear HO2S electrical connector (2). 11. Remove the left rear HO2S electrical connector clip from the frame. 12. For vehicles equipped with 2 wheel drive (2WD) perform the following steps, for vehicles equipped with 4 wheel drive (4WD) proceed to step 15. 13. Remove the left front CPA retainer. 14. Disconnect the left front HO2S electrical connector (7) from the engine wiring harness electrical connector (6). Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 6284 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 17032 Vehicle Zoning Strategy Truck Zoning Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Page 5305 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 9879 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 1782 Air Flow Meter/Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 11151 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 15387 Brake Hose/Line: Service and Repair Rear Brake Hose Replacement (Caliper - JD9) Rear Brake Hose Replacement (Caliper - JD9) Page 11982 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 22652 Seat Lumbar Switch - Driver (AN3) Seat Lumbar Switch - Passenger (AN3) Page 14323 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Page 11225 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 13401 This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 - Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Page 19464 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Page 430 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 4890 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 17011 Page 17598 3. Determine the caster angle (2). 4. Determine the positive camber (2) or negative camber (3) angle. 5. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 6. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice. 7. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Tighten the cam nuts to 190 N.m (140 lb ft). 8. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications. When the caster and camber are within specifications, adjust the toe. Front Toe Adjustment Front Toe Adjustment Page 5191 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 7985 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 15214 Page 14801 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 2698 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 3953 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 5039 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 2637 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 17268 For vehicles repaired under warranty, use the table. Disclaimer Page 19194 Disclaimer Page 11808 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 24236 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 8919 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 12122 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 2015 Page 3968 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Electrical - Various Electrical Malfunction/Systems Inop Wiper Motor: Customer Interest Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 14578 Notice: Refer to Fastener Notice. 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 N.m (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 7361 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 6719 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 19176 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 19923 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Page 15874 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 5005 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 8333 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 1811 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 122 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Driver Information Display Switch Replacement (without RPO SLT) Driver/Vehicle Information Display: Service and Repair Driver Information Display Switch Replacement (without RPO SLT) Driver Information Display Switch Replacement (without RPO SLT) Page 9678 Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice Excessive Force and Oxygen Sensor Notice Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Page 6680 Page 2080 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Rear Side Door Window Regulator Replacement (Crew Cab, Manual) Page 11585 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 16138 Page 5547 Disclaimer Page 23785 For vehicles repaired under warranty, use the table. Disclaimer Page 16414 X214 Inline Harness Connector End Views X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Page 5515 15. For vehicles equipped with 4WD perform the following steps, remove the left front CPA retainer. 16. Disconnect the engine wiring harness electrical connector (7) from the left front HO2S electrical connector (8). 17. Remove the left front HO2S electrical connector clip from the fuel line clip (2). 18. Remove the catalytic converter to muffler nuts. Page 8527 Page 16439 X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Page 10209 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 19675 Disclaimer Page 4637 3. Install the drain plug. Tighten the plug to 25 N.m (18 lb ft). 4. Lower the vehicle. 5. Fill the engine with the proper capacity and quality of engine oil. Refer to Approximate Fluid Capacities. 6. Operate the engine, check for leaks, and oil pressure. Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 20070 Page 11682 View of the connector when released from the component. View of another type of Micro 64 connector. Page 9683 Tighten the sensor to 42 N.m (31 lb ft). 3. If vehicle is a 4WD perform the following steps otherwise proceed to step 7. 4. Install the HO2S pigtail electrical connector clip (9) to the fuel line bracket. 5. Connect the engine wiring harness electrical connector (7) to the HO2S pigtail electrical connector (8). 6. Connect the CPA retainer. 7. If vehicle is a 2WD perform the following steps, connect the HO2S pigtail electrical connector (7) to the engine wiring harness electrical connector (6). 8. Connect the CPA retainer. 9. Lower the vehicle. Page 7121 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 8423 View of the connector when released from the component. View of another type of Micro 64 connector. Page 16782 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 12635 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or greater. 6. Remove the TCC PCS retaining bolt and retaining bracket. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Page 10748 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 16287 Junction Block - Right I/P X5 Interior - Wear Spots On Vinyl/Rubber Floor Covering Carpet: All Technical Service Bulletins Interior - Wear Spots On Vinyl/Rubber Floor Covering TECHNICAL Bulletin No.: 08-08-110-013 Date: August 18, 2008 Subject: Premature Wear or Worn Spots on Rubber/Vinyl Floor Covering (Replace Floor Covering) Models: 2007-2009 Chevrolet Silverado, Silverado HD, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra HD, Yukon, Yukon XL with Rubber Floor Covering (RPO BG9) Including Police (RPO PPV) and Municipal (RPO 5W4) Vehicles EXCLUDING Standard and Crew Cab Models Condition Some customers may comment on premature wear or worn spots (1) on the front rubber/vinyl floor covering. Correction Important: The standard and crew cab models already have the updated floor mat material. Replace the affected floor covering. Refer to Floor Panel Carpet Replacement in SI. The mat floor covering material has been updated to reduce premature wear. Parts Information Page 16478 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Page 2304 5. Remove the knock sensor bolt and sensor. Installation Procedure Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Service and Repair Spoiler: Service and Repair Rear Spoiler Replacement (901/902) Page 24160 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 13026 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 16590 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). Page 19262 Alarm Module: Service and Repair Theft Deterrent Module Replacement Page 10407 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 22945 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Capacity Specifications Fluid - A/T: Capacity Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Capacity Specifications Pan Removal ....................................................................................................................................... ........................................................ 4.7 liters (5.0 qts) Overhaul .............................................................................................................................................. .................................................. 10.6 liters (11.0 qts) Dry Fill W/ 300 mm Torque Converter.................................................................................................. ............................................... 11.5 Liters (12.1 qts) Measurements are approximate Allison - Automatic Transmission Fluid Capacity Specifications Allison 1000 Initial Fill ............................................................................................................................................... ................................................. 12.0 liters (12.7 qts) Refill ..................................................................................................................................................... .................................................... 7.0 liters (7.4 qts) Measurements are approximate 6L50/6L80/6L90 - Automatic Transmission 6L80 Trans Pan Removal .................................................................................................................... ..................................................................... 5.7 liters (6.0 quarts) Overhaul Capacity ....................... ....................................................................................................................................................... 9.9 liters (10.5 quarts) Complete System Capacity ................................................................................... ............................................................................ 11.7 liters (12.4 quarts) 6L90 Trans Pan Removal .................................................................................................................... ..................................................................... 6.0 liters (6.3 quarts) Overhaul Capacity ....................... ....................................................................................................................................................... 9.9 liters (10.5 quarts) Complete System Capacity ................................................................................... ............................................................................ 11.7 liters (12.4 quarts) Approximate Capacities Page 1588 Coolant Temperature Sensor/Switch (For Computer): Diagrams Engine Controls Connector End Views Engine Coolant Temperature (ECT) Sensor Page 3966 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 3035 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 18213 Page 18390 Disclaimer Page 13217 Fluid Line/Hose: Technical Service Bulletins A/T - Cooler Line Fitting Applications Bulletin No.: 08-07-30-004 Date: January 31, 2008 INFORMATION Subject: 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70 M32, M33, MK2 MD6) Oil Cooler Fitting Change Models: 1997-2008 GM Light Duty Trucks (Including Saab) with 4L60-E, 4L65-E, 4L70-E HYDRA-MATIC(R) Automatic Transmission (RPOs M30, M70, M3, M33, MK2, MD6) Aluminum cooler line fittings - These new fittings (2) cannot be used on earlier cases because the threaded hole is not the same size. Old style fittings (1) will continue to be available through SPO parts. Service cases will be the new case and fittings. The old cases with the old thread design will not be maintained for service. The connection on the hose side will accept both the short snout and the newer longer snout cooler hose assemblies. The fittings (1) have a new torque specification of 20 N.m (14 lb ft). They also have one inner and one outer "0" ring that are not serviced separately. Page 2923 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 6579 Page 2027 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 22541 For vehicles repaired under warranty, use the table. Disclaimer Page 5170 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. A/C - Control Module A/C Indicator Blinking Control Module HVAC: All Technical Service Bulletins A/C - Control Module A/C Indicator Blinking Bulletin No.: 07-01-38-006 Date: August 20, 2007 INFORMATION Subject: Information For Vehicles with HVAC Control Module A/C Indicator Blinking Due to Low Battery State of Charge Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Manual Temperature Control HVAC System (RPO CJ3) An Air Condition (A/C) button on the Heating, Ventilation and Air Conditioning (HVAC) control module may blink when the A/C system is activated. The blinking indicator will turn to a solid light after cycling the A/C button or ignition key. This condition may be caused by a low battery state of charge on a PREVIOUS ignition key cycle. This condition may be due to situations were an unsold vehicle is parked for long periods of time as part of a dealership's unsold inventory. The A/C indicator begins to flash if the battery voltage falls below 9.5 volts. The low voltage condition may occur during an engine crank or if the vehicle is parked and a normal battery state of charge is not maintained. If the A/C indicator continues to blink, use the Tech 2(R) to help determine the cause. Connect the Tech 2 and build the vehicle. Select Powertrain. Select Engine Control Module (ECM). Select Data Display. Select Cooling/HVAC data. Make sure that there has been an A/C request signal. History should indicate any causes. If necessary, refer to SI for further information on HVAC system diagnostic procedures. Page 8066 Page 11522 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 5073 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 24232 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 7799 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2514 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 23192 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 12112 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 22369 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 993 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 16807 Warranty Information (Saab U.S. Models) Disclaimer Page 5410 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 8288 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 13932 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 11345 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Caution Caution: Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 6241 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 2958 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 1971 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 10833 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 2649 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 22422 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 16976 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 9976 8. Install the catalytic converter to muffler nuts. Tighten the nuts to 45 N.m (33 lb ft). 9. For vehicles equipped with 4WD perform the following steps, for vehicles equipped with 2WD proceed to step 13. 10. Connect the engine wiring harness electrical connector (6) to the left front HO2S electrical connector (7). 11. Install the CPA retainer. 12. Install the HO2S electrical connector clip to the fuel line clip (2). Page 20377 Page 19160 Disclaimer Page 17295 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6) Page 14417 For vehicles repaired under warranty, use the table. Disclaimer Page 21000 Rear Door Striker: Service and Repair Door Striker Replacement (Extended Cab, Lower) Door Striker Replacement (Extended Cab, Lower) Removal Procedure Important: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the door lower striker bolts (1). 2. Remove the spacer, if equipped. 3. Remove the door lower striker (2). Installation Procedure Page 12704 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 11209 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 12219 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 18141 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Caution: To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Important: * Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. * Inspect the wheel for cracks. If cracks are found, discard the wheel. * ALL wheels with bent rim flanges must not be repaired or refinished. * The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. * Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options * Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). * If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option number 2). * Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources * The Paint Manufacturer's Color Book * Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. * To access the booklet, go to www.gmgoodwrench.com. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. * A Color Compatibility chart is also at this site defining what colors are used on what models. Important: Chemical strippers are not recommended. * Refer to specific Paint Manufacturers for refinish procedures and process pertaining to "Aluminum Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection * If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. * Some specific colors may be recommended on certain models. * If painting wheels that were previously clearcoated aluminum, it is recommended that all 4 wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures - Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. Important: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. Page 10787 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Page 19824 Page 5284 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 24500 Disclaimer Service Procedure Service Procedure Technicians are to confirm that the customer is aware that this safety recall is being performed on their vehicle prior to performing the repair. If a customer refuses to have this safety recall performed on their vehicle, dealers are to provide the customer with a copy of the "Notice to Customer" document provided in this bulletin, record on the repair order "customer declined recall repair" and, if possible, have the customer sign the repair order. A labor code is provided for customers who refuse the repair. This labor code will not close the recall. If the customer, or a new owner, decides at a later date to have the recall performed, perform the repair and submit the claim using the appropriate V labor code. This service procedure will permanently disable and remove the heated windshield washer fluid system. After performing the procedure, dealers are to issue a $100 USD/$105 CDN check to the customer of record as compensation for the loss of this feature (see Q&A; section of this bulletin for additional details). Involved vehicles currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Fuse Removal FUSE REMOVAL 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, 2007-2009 Chevrolet Avalanche, Silverado (GMT900), Suburban, Tahoe, 2007-2009 GMC Sierra (GMT900), Yukon and Yukon XL 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block is located in the engine compartment on the driver side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) Skid Plate: Service and Repair Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) Oil Pan Skid Plate Replacement (2500/3500 with RPO NZZ) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 2. Remove the mounting bolts for the oil pan skid plate. 3. Remove the oil pan skid plate. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . 5. Remove the mounting bolts for the oil pan skid plate. 6. Remove the oil pan skid plate. Installation Procedure Page 23576 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 6153 Camshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 21563 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 1510 Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement (w/o KB6) Page 14178 3. Install the pinion yoke. Align the marks made during removal. Notice: Refer to Pinion Flange/Yoke Installation Notice. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a NEW pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. Notice: Refer to Fastener Notice. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 7. Tighten the pinion nut while holding the J 8614-01. Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3-5 lb in) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. Page 17347 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Locations Audible Warning Device Control Module: Locations Displays and Gages Component Views Chime Module (UL5) 1 - Chime Module (UL5) Page 12811 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 17750 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Page 11886 Vehicle Zoning Strategy Truck Zoning Page 4992 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 17105 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 5085 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Electrical Symbols Electrical Symbols Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 17248 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Windshield Outside Moisture Sensor Replacement Rain Sensor: Service and Repair Windshield Outside Moisture Sensor Replacement Windshield Outside Moisture Sensor Replacement Page 1168 Page 935 Engine Control Module: Locations Engine Controls Component Views Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 22328 Front Seat Cushion Rear Frame Center Cover Replacement Page 16929 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 2494 View of the connector when released from the component. View of another type of Micro 64 connector. Page 16415 X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Page 7140 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 626 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 12520 Page 17044 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 13162 14. Remove the indicator tube bolt, if equipped with RPO HP2. 15. Remove the oil level indicator tube. 16. Remove the seal from the transmission, if necessary. Page 14300 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. 21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. For the 2500 and 3500 models, use the J 36652-2. 25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652-1 or J 36652-2. Page 505 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. A/T - Poor Performance/MIL ON/DTC P0757 Valve Body: Customer Interest A/T - Poor Performance/MIL ON/DTC P0757 Bulletin No.: 01-07-30-038D Date: September 12, 2006 TECHNICAL Subject: Diagnostic Trouble Code (DTC) P0757 Set, Malfunction Indicator Lamp (MIL) Illuminated, Poor Performance of Transmission, Transmission Slipping (Clean Transmission Valve Body and Case Oil Passages of Debris) Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X with 4L60-E/4L65-E/4L70-E Automatic Transmission (RPOs M30/M32/M70) Supercede: This bulletin is being revised to add the 2007 model year and the 4L70-E transmission. Also, information has been added to Condition, Cause and Correction. Please discard Corporate Bulletin Number 01-07-30-038C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: An illuminated MIL where DTC P0757 is found as a history code in the PCM or TCM. No 3rd and 4th gear. The transmission does not shift correctly. The transmission feels like it shifts to Neutral or a loss of drive occurs. The vehicle free wheels above 48 km/h (30 mph). High RPM needed to overcome the free wheeling. Cause This condition may be caused by any of the following: Page 24129 Turn Signal Bulb: Service and Repair Park/Turn Signal Lamp Bulb Replacement (GMC) Park/Turn Signal Lamp Bulb Replacement (GMC) Page 13534 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 21816 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 8561 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 7756 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 8545 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10598 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 11383 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 12549 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Rear Side Door Hinge Cover Replacement Rear Door Hinge: Service and Repair Rear Side Door Hinge Cover Replacement Rear Side Door Hinge Cover Replacement Page 6982 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 13753 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 15075 Transmission Mode Switch: Locations Shift Lock Control Component Views Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 17903 Install the front suspension spring and related components in the spring compressor. The fingers for the spring compression must be adjusted so that the spring is properly seated in the spring compressor. Adjust the fingers (1) for the spring compressor (2) on the front suspension mount (3) so that the fingers (1) are properly seated on the top of the front suspension strut mount (3). Align the upper spring seat, spring, and the shock absorber as noted during disassembly. Using the J 45400 (1), compress the spring assembly (2) enough to install the NEW nut (3). Install the shock absorber (4). Refer to Fastener Notice. Install the NEW nut (3). Tighten Page 10800 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 21672 Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 20082 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 10487 Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures Fuel Injector Replacement Page 5442 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 16513 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Heater Inlet Hose Replacement (Non-HP2) Heater Hose: Service and Repair Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. Page 5785 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 17066 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 22065 Page 15404 Page 21055 Page 20073 Central Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Initial Inspection and Diagnostic Overview Seat Heater: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Seats Begin the system diagnosis with the Diagnostic System Check - Vehicle. The Diagnostic System Check will provide the following information: * The identification of the control modules which command the system. * The ability of the control modules to communicate through the serial data circuit. * The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Page 21720 Memory Seat Module X7 (AN3) Page 2405 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 7616 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 15460 Parking Brake Cable: Removal and Replacement Parking Brake Intermediate Cable Replacement (JD9, JF3, JF7) Parking Brake Intermediate Cable Replacement (JD9, JF3, JF7) Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the front park brake cable (2) from the intermediate cable connector by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector (1). 5. Disconnect the left park brake cable (1) and the right park brake cable (2) from the equalizer bar (3) on the intermediate park brake cable. 6. Remove the intermediate park brake cable. Page 6754 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 3114 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 12196 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 646 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 6187 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 9610 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 23951 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 16899 Page 5926 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 19119 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended Cab +ASF) Inflatable Restraint Vehicle Rollover Sensor (ASF) Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Locations Air Bag Deactivation Switch: Locations SIR Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Fuel System - Driveability Issues/MIL/Multiple DTC's Fuel Injector: All Technical Service Bulletins Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Page 24059 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 9504 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 20511 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 4650 11. Remove the engine harness and transmission tube bracket (1). 12. Remove two engine wire harness bracket bolts (1). Page 16297 Fuse Block - Underhood X2 (Pin N1 To P5) Fuse Block - Underhood X3 Service and Repair Cabin Air Filter: Service and Repair This vehicle is not equipped with a factory installed passenger compartment air filter. Page 6584 Page 22453 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 10327 For vehicles repaired under warranty, use the table above. Disclaimer Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Fuel Hose/Pipes Replacement - Chassis (Extended Cab w/8 Ft Bed) Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Extended Cab w/8 Ft Bed) Fuel Hose/Pipes Replacement - Chassis (Extended Cab - w/8 Ft Bed) Removal Procedure Important: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. 3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. Page 195 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 4643 Oil Filter Adapter: Service and Repair Oil Filter Bypass Valve Replacement Oil Filter Bypass Valve Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Position a suitable container under the vehicle to catch the oil. 3. Remove the oil filter. 4. Using a suitable prying tool, remove the oil filter bypass valve. 5. Clean and inspect the valve bore for damage. Installation Procedure 1. Install a NEW oil filter bypass valve using the following procedure: 1. Use a brass drift that is the same diameter as the outside diameter of the oil filter bypass valve. 2. Install the oil filter bypass valve into the oil gallery bore until slightly below flush with the surface of the engine block. 3. Using a pointed punch, stake the engine block area around the oil filter bypass valve. Stake in 3 locations 120 degrees apart. Page 12845 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 4521 7. Disconnect the following electrical connectors: * The ignition coil (1) * The ignition coil drive (2) * The generator (3) 8. Disconnect the engine wiring harness clips. 9. Reposition the engine wiring harness. Page 10475 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 13518 Page 12986 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 13679 1. Place the steering column shift lever back into the park (P) position. 2. Raise the vehicle. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat-bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end. 5. Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 6. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 7. Pull the white cover (5) on the shifter end (1) back. 8. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). Page 17287 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Page 5745 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 3862 Page 7243 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 8193 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 6235 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 8477 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 4112 Page 17827 Ball Joint: Technical Service Bulletins Suspension - Revised Front Lower Ball Joint Nut Torque INFORMATION Bulletin No.: 09-03-08-001A Date: March 17, 2009 Subject: Revised Front Lower Ball Joint Nut Service Procedure Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to change information on the lower ball joint nut. Please discard Corporate Bulletin Number 09-03-08-001 (03 - Suspension). For service, GM P/N 15046285 is the current nut to use. Tighten the nut to 125 Nm (92 lb ft). Disclaimer Page 6613 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 19221 11 - Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) 12 - Seat Adjuster Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Page 11405 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 3437 Window Switch - Passenger (A31 -AN3/DL3) Window Switch - Right Rear (Crew Cab +A31/Extended Cab +ABV) Page 2081 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 6647 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 13482 Transmission Position Switch/Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft Position Switch Replacement Page 22976 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 3153 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 18027 Notice: Refer to Fastener Notice. 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 N.m (62 lb in). Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. Install the tire on the wheel. Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 9531 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 13799 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 4161 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Page 21632 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 3335 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: * M6 X 1.0 X 65.0 (1) * M6 X 1.0 X 54.4 (2) * M6 X 1.0 X 47.5 (3) * M6 X 1.0 X 35.0 (4) * M8 X 1.0 X 20.0 (5) * M6 X 1.0 X 12.0 (6) * M6 X 1.0 X 18.0 (7) Page 15346 Page 14871 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 8179 5. Disengage the retainer tabs securing the ECM to the bracket. 6. Remove the ECM. Installation Procedure 1. Install the bottom ECM tabs into the bracket. 2. Push the ECM in securing the ECM to the bracket. Page 23739 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 8367 The data link connector (DLC) is a standardized 16-cavity connector. The DLC low speed serial data circuit is connected directly to the instrument panel (I/P) splice then to all other splices or modules. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Pin 1 GMLAN low speed communications terminal * Pin 4 scan tool power ground terminal * Pin 5 common signal ground terminal * Pin 6 high speed GMLAN serial data bus (+) terminal * Pin 14 high speed GMLAN serial data bus (-) terminal * Pin 16 scan tool power, battery positive voltage terminal Serial Data Reference The scan tool communicates over the various busses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No COMM for that options specific control module. In order to avert misdiagnoses of No Communication with a specific module, refer to Data Link References for a list of modules, the busses they communicate with, and the RPO codes for a specific module. See: Data Link Connector/Testing and Inspection Page 3456 Washer Fluid Level Switch: Diagrams Wiper/Washer Connector End Views Washer Fluid Level Switch Page 3990 Locations Knock Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 3978 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 12592 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 22415 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 1201 Air Bag Control Module: Locations SIR Component Views Under the Front Seats 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Page 14798 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 10344 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 15450 Disclaimer Page 14788 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 5298 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 7320 Page 20199 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Page 9350 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 21918 11 - Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) 12 - Seat Adjuster Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Page 11945 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. A/C - Compressor/Serpentine Belt Noise Drive Belt: Customer Interest A/C - Compressor/Serpentine Belt Noise TECHNICAL Bulletin No.: 07-01-38-010A Date: October 06, 2009 Subject: Air Conditioning (A/C) Compressor and/or Serpentine Belt Noise at Vehicle Start-up (Reprogram Powertrain Control Module (PCM)) Models: 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon Models Equipped With Air Conditioning (RPOs CJ2 or CJ3) Supercede: This bulletin is being revised to update the Condition and Correction information. Please discard Corporate Bulletin Number 07-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on air conditioning (A/C) compressor slugging and/or serpentine belt or pulley rattle noise at vehicle start-up in warmer outside ambient temperature conditions. Others may describe the noise as a belt chirp or as a thumping/grinding noise coming from the A/C compressor at vehicle start-up. Cause This condition may be caused by the A/C compressor trying to move liquid refrigerant through the system. Correction - A revised PCM calibration has been released to address this condition. Reprogram the PCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. - When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. - When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. - During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information Note *Please use Failure Code 93 for any warranty claims submitted using this bulletin. For vehicles repaired under warranty, use the table above. Page 17114 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 12693 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 23138 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 14869 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 7266 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Interior - Front Power Seat Adjust/Memory Inoperative Power Seat Switch: Customer Interest Interior - Front Power Seat Adjust/Memory Inoperative Bulletin No.: 06-08-50-012 Date: October 06, 2006 TECHNICAL Subject: Front Driver or Passenger Power Seat Adjust Functions Inoperative and/or Driver Seat Memory Inoperative (Check Power Seat Switch Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (New Style), Suburban, Tahoe 2007 GMC Sierra (New Style), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the front driver or passenger power seat adjust functions are inoperative. They may also comment that the driver seat memory is inoperative. Cause The cause of this condition may be due to the power seat switch connector not being fully seated. Correction Remove the front seat cushion outer trim panel following the replacement procedure in SI. Verify that the power seat switch connector is fully seated. Reseat the connector and test the seat functions. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7542 Page 12880 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 3196 1 - Door Frame 2 - Window Switch - Left Rear (A31) 3 - Window Motor - Left Rear (A31) 4 Speaker - Left Rear Door 5 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 6 Door Latch Assembly - Left Rear Right Rear Door (Crew Cab) Page 6287 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 11968 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 8560 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 24078 Headlamp Switch: Service and Repair Headlamp Switch Replacement (without RPO SLT) Headlamp Switch Replacement (without RPO SLT) Page 17181 Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Page 16202 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 24664 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 16283 Junction Block - Right I/P (Wire Entry) (Pin 2A1 To 4B6) Page 5986 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 3662 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 3457 Washer Fluid Level Switch: Service and Repair Washer Solvent Container Level Sensor Replacement (Chevrolet) Page 23004 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 2950 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 14906 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 942 Page 7598 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 7025 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 11662 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 6934 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Instruments/Audio - No Speaker Audio/Warning Chimes Amplifier: Customer Interest Instruments/Audio - No Speaker Audio/Warning Chimes Bulletin No.: 07-08-44-008 Date: April 18, 2007 TECHNICAL Subject: No Audio/No Sound Heard from Radio Speakers, Turn Signals, Hazard Signals and No Warning Chimes When a Door or Liftgate is Opened (Inspect/Seat C2 Audio Amplifier Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Speakers, Premium Audio w/Amplifier or Rear Stereo Audio (RPOs UQA, UQS or UK6) Condition Some customers may comment on one or all of the following conditions related to no audio/no sound: No sound from one or more of the radio speakers. No blinking sound heard form the turn signals or hazard signals when on. No audio warning chimes heard when a door or liftgate is opened. Cause The C2 Audio Amplifier Connector may become unseated at the amplifier. Correction Inspect/Seat the C2 Audio Amplifier Connector (16-way, Black Connector). Remove the radio, amplifier, and SIR fuses located in the Underhood Bussed Electrical Center (BEC). Gain access to the radio speaker amplifier. Refer to Radio Speaker Amplifier Replacement in SI. Page 2679 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. OnStar(R) - False Crash Detection Customer Calling Emergency Contact Module: All Technical Service Bulletins OnStar(R) - False Crash Detection Customer Calling TECHNICAL Bulletin No.: 08-08-46-002 Date: June 26, 2008 Subject: OnStar(R) Calls Unwanted, False Crash Detection Customer Calling (Reprogram SDM) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with OnStar(R) (RPO UE1) Condition Some customers may comment on receiving unwanted calls from the OnStar(R) Center. Cause During certain extreme vehicle maneuvers, the vehicle SDM may mistakenly detect a crash event and generate a call to the OnStar(R) call Center. The OnStar(R) advisor is connected to the vehicle to see if everyone is alright and if a request for emergency help is needed. Correction A revised SDM Operating System software has been developed to address this issue. Reprogram the Sensing and Diagnostic Module (SDM) with the controller option described as "SDM Sensing and Diagnostic Module" under Operating System using the TIS2WEB Service Programming System (SPS) application. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 23272 Page 9791 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 66 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 22783 7. Repeat steps 5 and 6 five more times to look for repeatability. If either one of the sides does not engage, manually close the latch that did not engage and inspect the latch closure of each side by wiggling each corner. Check for the following: 1. If one side is too loose and exhibiting excessive movement, lower the corresponding loop per steps 3.1-3.4 in the Up and Down Adjustment section above. 2. If one side requires excess manual efforts to close, raise the corresponding loop using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Raise the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). Inspect/Adjust Latch Release Operation 1. Open the tonneau cover. 2. Manually push the U-shaped catches closed for both sides of the vehicle. If either one of the catches does not close, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Push the cable inboard from the end of cable to add length to the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should engage at the same time. 4. Inspect the timing of the latch engagement by manually closing the latches and twisting the lock handle with the cover in the open position. If the latches do not engage at the same time, repeat the above adjustment until they do. 3. Twist the handle and listen for the latches to release. If either one of the catches does not open, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Pull the cable outboard from the end of the cable to shorten the length of the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should release at the same time. 4. Inspect the timing of latch release. Repeat steps 3.1-3.3 above, adjusting the latch that releases second, until both latches are releasing at the same time. Verify that the front frame is centered and squared onto the pickup box 1. Measure from the edge of the front panel sheet metal cross-car to the edge of the hinge clip on both sides. Loosen hardware and adjust the frame position side to side until it's centered. 2. Measure from the stack pocket to the end of the side frame on both sides. Loosen hardware and adjust the frame position until both sides match. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: Customer Interest Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Page 10457 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4019 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Transmission Fluid Temperature Sensor Specifications Page 20248 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 13596 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Locations Alarm Module: Locations Immobilizer Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 468 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 11452 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 11768 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 23075 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 15855 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 2499 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Instruments - Hard to See/Poor Backlighting Instrument Panel Control Module: Customer Interest Instruments - Hard to See/Poor Backlighting Bulletin No.: 07-08-49-029A Date: January 25, 2008 TECHNICAL Subject: Instrument Panel (IP) Gauges/Gages Difficult to Read or See Poor Backlighting (Replace IP and Program) Models: 2007 Chevrolet Avalanche Silverado Suburban Tahoe 2007 GMC Sierra Sierra Denali Yukon Yukon Denali Yukon XL Yukon Denali XL Supercede: This bulletin is being revised to reflect the latest Utility software part number. Please discard Corporate Bulletin Number 07-08-49-029 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) gauges are difficult to read due to poor backlighting. This condition does not affect the IP cluster operation. Correction DO NOT program the service software into existing 2007 clusters. The service software is designed to work only with the 2008 cluster hardware, which includes a new microprocessor. For IP clusters replaced/programmed due to a customer concern of poor backlighting, warranty claims must be submitted using the labor operation listed in this bulletin. Refer to the Warranty Section for more information. Program the replacement IPC using TIS2WEB Pass-Thru Programming. Select "I/PC" from the Supported Controllers table in TIS2WEB to complete the programming. DO NOT select I/PC Set-up. Mileage and/or Engine Hours must be set by the ESC's prior to installing the IP in the vehicle. DENALI CUSTOMER'S ONLY - Please advise the customer that 2008 Denali clusters are not available. In order to correct this condition, a 2008 Yukon or Sierra cluster will have to be installed in the vehicle. The customer must advise the dealer whether they wish to keep the current 2007 Denali cluster or replace it with a 2008 Yukon or Sierra cluster (which will correct the condition). Programming a 2007 cluster with the 2008 service software can drain the battery and potentially cause a "no start" condition. If the customer is dissatisfied with the IP cluster visibility the current (2007) cluster should be replaced with the 2008 hardware/software. Refer to the charts listed in the Parts Information section of this bulletin to determine the new IP cluster and software part numbers. Page 20664 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 14919 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 21880 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 3325 Fluid Pressure Sensor/Switch: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Service and Repair Engine Block Heater: Service and Repair Coolant Heater Replacement (LU3) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Disconnect the heater cord from the coolant heater (4). 3. Loosen the coolant heater bolt. 4. Remove the coolant heater from the engine block. 5. Do not score the machined surface of the hole. 6. Grasp the plug with pliers. 7. Pull the plug from the engine block. 8. Clean the core plug hole in order to remove the following substances: * Burrs * Compound * Paint * Rough spots Installation Procedure 1. Coat the O-ring seal and the cleaned surface of the plug opening with water resistant high-temperature grease lubricant GM P/N 9985164 (Canadian P/N 10953480), or the equivalent. Important: Avoid element contact with the inside walls of the engine block. 2. Tightly push the coolant heater (1) into the engine block. Notice: Refer to Fastener Notice. Page 11165 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 17092 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 4147 Fuse Block - Underhood X1 Page 21884 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 3552 For vehicles repaired under warranty, use the table. Disclaimer Page 1031 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 21606 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 16996 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 10871 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 10356 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 16739 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 5153 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 14731 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 3483 Alignment: Testing and Inspection Trim Height Inspection Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can the vehicle to cause bottom out over bumps, damage to the suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label. * Check the fuel level. Add additional weight if necessary to simulate a full tank of gas. (One U.S. gallon of gasoline weights approximate 6.5 lbs. One liter of gasoline weights 0.70 kg) * Make sure the passenger and rear compartments are empty, except for the spare tire. * Make sure the vehicle is on a level surface, such as an alignment rack. * For vehicles equipped with automatic level control, make sure that the system is functioning properly. * Make sure that all doors, lift gate/trunk and the hood are securely closed. * Check for installed after market accessories or modifications that could affect trim height measurements: - Larger or smaller than production wheels and tires - Lifting or lowering kits - Wheel opening flares - Ground affects * Remove the alignment rack floating pins. Measuring the Z Height Important: For vehicles equipped with torsion bars, the Z height must be verified before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use a adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. Important: All dimensions are measured vertical to ground. Cross vehicle Z heights should be within 12 mm (0.47 in) to be considered correct. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Locations Central Control Module: Locations Entertainment/Communication Component Views Behind the I/P 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 +YE9) 6 - Digital Radio Receiver (U2K) Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 7601 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 2103 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 22102 Head Rest: Service and Repair Head Restraint Guide Replacement Head Restraint Guide Replacement Page 4017 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Body - Roof Panel Flutters/Rattle Noise When Doors Close Headliner: Customer Interest Body - Roof Panel Flutters/Rattle Noise When Doors Close TECHNICAL Bulletin No.: 08-08-67-016F Date: January 24, 2011 Subject: Roof Panel Flutters or Rattle Noise from Roof or Headliner when Closing Doors (Apply Foam) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Models Only), Suburban, Tahoe 2010-2011 Chevrolet Equinox 2007-2009 GMC Sierra (Crew Cab Models Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2010-2011 GMC Terrain Supercede: This bulletin is being revised to add the 2011 model year to Equinox/Terrain models. Please discard Corporate Bulletin Number 08-08-67-016E (Section 08 - Body and Accessories). Condition Some customers may comment that the roof panel flutters and/or there is a rattle noise from the roof or headliner when closing one of the side doors or the liftgate. Cause This may be caused by the excessive motion of the roof panel. On initial inspection, you may notice that the roof panel expansion adhesive material has separated between the roof and the roof bow. The concern is seen mostly on the first cross bow. Correction Lower the headliner assembly (it is not usually necessary to remove the headliner from the vehicle) to gain access to the roof bows. Refer to Headlining Trim Panel Replacement in SI. Remove any loose foam from the roof bow or bows. Apply Fusor super flexible anti-flutter foam-fast set, Fusor P/N 121/124, or equivalent, in a continuous bead the entire length between the roof bow reinforcement and the roof outer panel. Reinstall the headliner. Refer to Headlining Trim Panel Replacement in SI. Parts Information Contact Lord Fusor at 1-877-275-5673 or on the Web at www.lord.com. Warranty Information For vehicles repaired under warranty, use the table. Page 4331 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Locations Hood Sensor/Switch (For Alarm): Locations Immobilizer Component Views Near the Hood Latch 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor - ISRVM Page 15274 If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism, refer to Brake Rotor Refinishing. After refinishing the rotor, proceed to step 14. 14. Mount a dial indicator, J 45101, or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 15. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 16. Compare the brake rotor assembled LRO to the following specification: Brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in) Brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Brake rotor maximum allowable assembled lateral runout: 0.25 mm (0.010 in) 17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction. See: Brake Rotor Assembled Lateral Runout Correction 18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. Page 11530 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 12673 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2350 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 6238 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 7927 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 22333 Front Seat Cushion Outer Trim Panel Replacement (Manual) Front Seat Cushion Outer Trim Panel Replacement (Manual) Page 15588 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (JH6/JH7) Electronic Brake Control Module (JH6/JH7) Page 16900 Page 956 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 15162 1 - Wheel Speed Sensor (WSS) - Left Rear (JL4) 2 - Wheel Speed Sensor (WSS) - Right Rear (JL4) Page 3745 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Page 2333 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 1111 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 16930 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Brake Rotor Assembled Lateral Runout Correction Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Important: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. See: Brake Rotor Thickness Measurement * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Brake Rotor Assembled Lateral Runout Measurement Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * Brake Rotor Assembled Lateral Runout Correction - Indexing The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. * Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Page 11559 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 12268 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Seals and Gaskets: Customer Interest A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 9620 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Displays and Gages Connector End Views Driver/Vehicle Information Display: Diagrams Displays and Gages Connector End Views Displays and Gages Connector End Views Driver Information Center (DIC) Switch Service and Repair Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement Tools Required j 3049-A Valve Lifter Remover Removal Procedure 1. Remove the intake manifold. 2. Remove the pushrods. Important: Place the components in a rack so that the components can be installed to their original location. 3. Remove the bolts and lifter pushrod guide. Important: Place the valve lifters in the rack in the upright position in order to maintain the oil inside the valve lifters. 4. Remove the lifters. Important: Some valve lifters may be stuck in the valve lifter bores because of gum or varnish deposits and may require the use of J 3049-A for removal. 5. Use the J 3049-A in order to remove the stuck valve lifters. 6. Use a cleaning solvent and a shop towel to clean any varnish from the valve lifter bores. Page 2773 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 24307 1 - Door Frame 2 - Window Switch - Left Rear (ABV) 3 - Speaker - Left Rear Door 4 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 5 - Window Motor - Left Rear (ABV) Right Rear Door (Extended Cab) Body - Side Window Chipping Information Front Door Window Glass: All Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Page 18624 Discharge Air Temperature Sensor / Switch: Diagrams HVAC Connector End Views Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Page 11838 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 4440 7. Inspect the lifter bores for excessive wear or scoring. Replace the engine block if there is excessive wear or deep scoring. 8. Inspect the camshaft for wear or damage. If the wear is questionable remove the camshaft and inspect. 9. Clean and inspect the lifters, if necessary. Refer to Valve Lifters and Guides Cleaning and Inspection. Installation Procedure Important: It is normal for NEW lifters to make a slight ticking noise when the engine is first started. Increasing the engine RPM slightly to raise oil pressure should stop the noise. 1. Apply lubricant to the lifter rollers. Refer to Sealers, Adhesives, and Lubricants for the correct part number. Important: If reusing the lifters, install the lifters to their original positions. 2. Install the lifters. Notice: Refer to Fastener Notice. 3. Install the lifter pushrod guides. Tighten the bolts to 16 N.m (12 lb ft). 4. Install the pushrods. 5. Install the intake manifold. Page 16083 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 8270 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 12812 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 2661 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 5017 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 1824 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 10452 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 8308 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 18155 Wheel Hub: Specifications Hub Nut ............................................................................................................................................... .................................................... 240 N.m (177 lb ft) Page 6222 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 11782 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 8200 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 10326 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Page 5810 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 12213 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 10874 Page 7222 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 9685 Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (4). Tighten the sensor to 42 N.m (31 lb ft). 3. Install the HO2S pigtail electrical connector clip (2) to the frame. Page 16255 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 19919 Page 16205 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Steering - Steering Wheel Off Center/Clunk When Turning Tie Rod: All Technical Service Bulletins Steering - Steering Wheel Off Center/Clunk When Turning Bulletin No.: 07-02-32-008A Date: November 21, 2007 TECHNICAL Subject: Steering Wheel Off Center While Driving Straight, Clunk Noise While Turning, Early Front Tire Wear (Perform Torque to Tighten Analysis and Repair as Necessary) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 1500 Series (1/2 Ton) Models Only Supercede: This bulletin is being revised to add additional conditions and update the correction information. Please discard Corporate Bulletin Number 07-02-32-008 (Section 02 - Steering). Condition Some customers may comment that the steering wheel is out of position (turned to the left or right) while driving straight ahead and/or a clunk noise while turning with early front tire wear. Cause The cause of condition may be due to the threaded joint between the inner tie rod and the rack loosening. Testing has shown it to be unlikely that the joint will unscrew (separate) during normal driving maneuvers, however the steering wheel alignment can be affected. Correction If the steering wheel is turned to the left while driving straight ahead, remove the right hand steering gear convoluted boot clamps. After exposing the tie rod connection to the rack bar, use a paint pen or marker and place an indexing mark from the tie rod to the rack bar. Check the "torque to tighten" on the tie rod to rack bar attachment by applying 50 N.m (37 lb ft) torque in a clockwise direction. Do not exceed this specification. Use of a 1-9/16" crowfoot is necessary. Hold the rack bar with a pipe wrench. If the steering wheel is turned rightward during the straight ahead driving, conduct the same analysis described above on the left hand tie rod. Inspect the inner tie rod and the rack bar for a change in position of the index mark with respect to each other. If any position change is observed, replace the steering gear. Please call a engineer to coordinate the return of the steering gear. Align the steering wheel and set toe. If no relative motion is observed between the tie rod and the rack bar during the 50 N.m (37 lb ft) "torque to tighten" analysis, do not replace any steering components. Reinstall the tie rod boot to the rack housing with a new crimp clamp, P/N 11562064. Align the steering wheel and set toe. In both cases, reuse the outer tie rod ends. Parts Information Warranty Information Page 23559 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 24339 For vehicles repaired under warranty, use the table. Disclaimer Page 2137 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 16056 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 7060 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 8839 Disclaimer Page 16392 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (4.3L/4.8L/5.3L) Page 20991 Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement (YE9) Rear Side Door Trim Panel Replacement (YE9) Page 8302 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11150 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 17754 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Page 4213 Notice: Refer to Fastener Notice. 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 N.m (62 lb in). Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. Install the tire on the wheel. Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 15098 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Audio System - Static/Ignition Noise on AM Band Ignition Cable: All Technical Service Bulletins Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Page 11112 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 6434 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 17375 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Page 19591 Garage Door Opener Transmitter: Diagrams Remote Function Connector End Views Garage Door Opener (UG1) Page 5825 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 17052 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 4586 5. Remove the engine mount bolts. (right side shown, left side similar). 6. Remove the engine mount. 7. If equipped and necessary, remove the engine mount side bracket bolts and bracket. (right side shown, left side similar). 8. Remove the engine mount bracket bolts. 9. Remove the engine mount bracket. Installation Procedure 1. Install the engine mount bracket. 2. Perform the following procedure prior to installing the engine mount bracket bolts. 1. Remove all traces of the original adhesive patch. Page 9930 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 9326 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 7879 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 17048 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 10103 9. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis line. 11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 12. Install the fuel line clip (1) to the bracket on the automatic transmission. Page 9587 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21597 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 5285 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 18783 Procedures Steering Angle Sensor: Procedures Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 7251 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 17493 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 23037 Visually inspect and pull on the C2 Audio Amplifier Connector (1). If the connector is properly seated, then refer to SI for further diagnosis based on the customers condition. If the connector is loose, then reinstall the C2 Audio Amplifier Connector. Verify the connector is seated and locked into place. Install the fuses. Verify the condition has been fixed and clear any DTCs. If securing the connector does not correct the condition, refer to SI for further diagnosis and repair. Install the radio speaker amplifier assembly and any other components removed to gain access to the amplifier. Refer to Radio Speaker Amplifier Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4892 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 16715 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 7468 4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 5. Install the air cleaner outlet resonator to the MAT/IAT sensor. 6. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). Page 15522 Vacuum Brake Booster: Diagrams Power Brake Booster (JL4) Power Brake Booster (JL4) Page 2486 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 12781 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (367A) and the 1-2 shift solenoid retainer (395). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. 4. Install the pressure control solenoid (377). Notice: Refer to Fastener Notice. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Page 5975 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Page 9329 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 9746 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 22325 Front Center Seat Cushion Cover and Pad Replacement (AE7) Front Center Seat Cushion Cover and Pad Replacement (AE7) Page 7397 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 17363 X214 Inline Harness Connector End Views X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Page 271 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 8547 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 5656 Disclaimer Page 8648 Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (3). Tighten the sensor to 42 N.m (31 lb ft). 3. Install the HO2S pigtail electrical connector clip to the engine wiring harness clip (3). Page 18957 When in the correct location, the latch plate tongue will be between the webbing and the seat. U.S. dealers: For additional information, search gmtraining.com's Web Video Library for the May 2007 Emerging Issues video (course #10207.05D). Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Locations Turn Signal Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 4672 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing 1. With the vehicle on a level surface, allow adequate drain down time, 2-3 minutes, and measure for a low engine oil level. Add the recommended grade engine oil, and fill the crankcase until the oil level measures FULL on the oil level indicator. 2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure gage or the oil indicator light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: * Engine oil diluted by moisture or unburned fuel mixtures * Improper engine oil viscosity for the expected temperature * Incorrect or faulty oil pressure gage sensor * Incorrect or faulty oil pressure gage * Plugged oil filter * Malfunctioning oil filter bypass valve 4. Remove the oil pressure gage sensor or another engine block oil gallery plug. 5. Install an oil pressure gage. 6. Start the engine and then allow the engine to reach normal operation temperature. 7. Measure the engine oil pressure at the following RPM: 1. 42 kPa (6 psig) minimum, at 1,000 RPM 2. 125 kPa (18 psig) minimum, at 2,000 RPM 3. 166 kPa (24 psig) minimum, at 4,000 RPM 8. If the engine oil pressure is below minimum specifications, inspect the engine for one or more of the following: * Oil pump worn or dirty * Malfunctioning oil pump pressure relief valve * Oil pump screen loose, plugged, or damaged * Excessive bearing clearance * Cracked, porous or restricted oil galleries * Engine block oil gallery plugs missing or incorrectly installed * Broken valve lifters Page 194 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Page 11041 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 14494 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 13693 Important: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support. 3. Install the range selector cable to the support. 4. Ensure that the transmission manual shaft lever is in the mechanical park position. 5. Install the cable to the steering column bracket. 6. Ensure the tangs fully seat (snap) into the steering column bracket. 7. Install the cable end to the steering column ball stud. Page 13437 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: * M6 X 1.0 X 65.0 (1) * M6 X 1.0 X 54.4 (2) * M6 X 1.0 X 47.5 (3) * M6 X 1.0 X 35.0 (4) * M8 X 1.0 X 20.0 (5) * M6 X 1.0 X 12.0 (6) * M6 X 1.0 X 18.0 (7) Page 2737 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12726 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 10621 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 16666 For vehicles repaired under warranty, use the table. Disclaimer Electrical - Multiple Electrical Concerns Wiring Harness: All Technical Service Bulletins Electrical - Multiple Electrical Concerns Bulletin No.: 07-08-49-018 Date: September 07, 2007 TECHNICAL Subject: Various Electrical Concerns - Intermittently Functioning or Inoperative Component, IP Warning Light On, DIC Message Displayed, DTC Set, No Crank/Start (Repair IP Wiring Harness) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on one of the driver notifications and/or effects shown above. Page 17080 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 5251 Radiator: Service and Repair Radiator Replacement Radiator Replacement (4.3, 4.8, 5.3, and 6.0L) Removal Procedure 1. Remove the cooling fan and shroud. 2. Remove the radiator outlet hose for the 4.3L engine, or the 4.8L, 5.3L and 6.0L engines. 3. Disconnect the engine oil cooler lines from the radiator, If Equipped. 4. Disconnect the transmission oil cooler lines from the radiator, If Equipped. 5. Remove the radiator bolts. 6. Remove the radiator. Installation Procedure 1. Install the radiator. Notice: Refer to Fastener Notice. 2. Install the radiator bolts. Tighten the bolts to 25 N.m (18 lb ft). 3. Connect the transmission oil cooler lines to the radiator, If Equipped. 4. Connect the engine oil cooler lines to the radiator, If Equipped. 6. Install the cooling fan and shroud. Page 5956 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 22443 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 16699 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 10931 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 16840 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 17128 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 6873 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 10233 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 22915 Page 24165 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 13567 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 21303 The outline portion (1) of the insulator should Only be removed if the vehicle is equipped with the manual 4x4 shifter. All other vehicles should use the complete piece. Remove the two protective paper strips (1) from the insulator. Attach the glue side of the insulator to the top of the floor tunnel as shown in the above illustration. Reposition the carpet or rubber floor covering back down into position. Install the body lock pillar trim panels. Refer to Body Lock Pillar Trim Replacement in SI. Install the jack and the jack handle kit. Refer to Jack Stowage Cover Replacement in SI. Install the IP support bracket, bolts and trim covers. Tighten Page 11379 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 23377 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 13537 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 21197 Transmission Support Crossmember Replacement (2WD 2500 HD/3500) Transmission Support Crossmember Replacement (2WD 2500 HD/3500) Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 16265 Part 1 Electrical Center Identification Views Junction Block - Left I/P, Top View Page 2332 Page 4055 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 1822 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 20515 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module 7 - Fuse Block - I/P Page 6352 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 12658 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 9710 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 24562 Scott Lawson General Director, Customer and Relationship Services Page 20242 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 15407 Page 10178 Page 5126 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 2121 Crankshaft Position Sensor: Connector Views Engine Controls Connector End Views Crankshaft Position (CKP) Sensor Page 7144 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 21460 Headliner: Service and Repair Headlining Trim Panel Replacement (Extended Cab) Headlining Trim Panel Replacement (Extended Cab) Page 8987 Page 3888 Page 4069 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Charging System - Volt Meter Fluctuation Information Volt Meter Gauge: Technical Service Bulletins Charging System - Volt Meter Fluctuation Information INFORMATION Bulletin No.: 07-06-03-009B Date: February 05, 2010 Subject: Information on Voltmeter Gauge Fluctuation Due to Regulated Voltage Control System and Concerns About Camper/Trailer Battery Charging Models: 2005-2010 Cadillac Escalade Models 2005-2010 Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2005-2010 GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 07-06-03-009A (Section 06 - Engine/Propulsion System). Voltmeter Fluctuation Condition Some customers may comment that the voltmeter is fluctuating between 12 and 14 volts on their full size pickup or utility vehicle. Starting with the 2005 model year, light duty full size pickups and utilities are equipped with a Regulated Voltage Control (RVC) system. This system reduces the targeted output of the generator to 12.6-13.1 volts when in "Fuel Economy Mode" to improve fuel economy. The generator may exit "Fuel Economy Mode" if additional voltage is required. This will cause the voltmeter to fluctuate between 12 and 14 volts as opposed to non-regulated systems that usually maintain a more consistent reading of 14 volts. This fluctuation with the RVC system is normal system operation and NO repairs should be attempted. Camper/Trailer Battery Charging Concerns Some customers may comment that when towing or hauling a camper/trailer, the auxiliary battery for the camper/trailer will not stay charged. In most cases, this concern is blamed on the new RVC system. While the RVC system does reduce the generator's targeted output voltage to 12.6-13.1 volts when in "Fuel Economy Mode", this feature is bypassed if the tow/haul feature is enabled. With the tow/haul feature enabled, the RVC system will stay in "Charge Mode" and the targeted generator output voltage will be 13.9-15.5 volts, depending on the battery state of charge and the estimated battery temperature. To keep the generator in the "Charge Mode", use either of the following two methods. - The first method is to use the tow/haul mode when towing or hauling a camper or trailer. - The second method is to turn on the headlights, which will increase the generator's targeted output voltage to 13.9-14.5 volts. Disclaimer Page 18651 Solar Sensor: Diagrams HVAC Connector End Views Ambient Light/Sunload Sensor Assembly Page 5291 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 10715 7. Position the fuel tank fill pipe ground wire to the frame bracket. 8. Install the fuel tank fill pipe ground wire anti-rotation tab into the frame hole. 9. Install the fuel tank fill pipe ground wire bolt. Tighten the bolt to 9 N.m (80 lb in). 10. Lower the vehicle. 11. Install the fuel tank filler housing. 12. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the screws to 2.3 N.m (20 lb in). 13. Install the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). Tighten the screws to 2.3 N.m (20 lb in). Page 16102 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12960 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 16380 Disclaimer Page 13247 Page 13313 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 2181 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 10254 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 23317 Frequently Asked Questions Disclaimer Page 6842 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Notice: Refer to Fastener Notice. 2. Install the accelerator pedal bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: Page 11465 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Reluctor Ring Replacement Crankshaft Position Sensor Reluctor Ring Replacement Tools Required j 5590 Rear Pinion Bearing Race Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position (CKP) sensor reluctor ring. Installation Procedure Page 11826 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 13620 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 8563 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 15865 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 3526 Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the air cleaner outlet resonator from the MAF/IAT sensor. 3. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. Page 11645 Page 1352 Page 23652 Page 4008 Page 14127 If a condition is found, clean the area and repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Lost Communication With DTC's Set Lost Communication with Various Control Modules and DTCs Set DTC Descriptors Note Depending on the vehicle there may be other DTCs set by other modules. - DTC U0073 Control Module Communication Bus A Off - DTC U0100 Lost Communication with Engine/Powertrain Control Module (ECM/PCM) - DTC U0101 Lost Communication with Transmission Control Module (TCM) - DTC U0102 Lost Communication with Transfer Case Control Module - DTC U0121 Lost Communication with Electronic Brake Control Module (EBCM) - DTC U0140 Lost Communication with Body Control Module (BCM) 1. Connect a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). If any DTC(s) are set, refer to the list above or the Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. Turn OFF the ignition and all accessories. 3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 4. Disconnect the connector(s) at the affected module. 5. Inspect the connector(s) for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) - Water intrusion ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI AND ‹› If corrosion or water intrusion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Reconnect the connector(s) at the affected modules. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Repairing Fretting Corrosion Repairing Fretting Corrosion Note Fretting corrosion looks like little dark smudges on the electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. 1. If any water intrusion is present in the connector, use pressure regulated compressed air to dry it out. 2. DO NOT apply an excessive amount of dielectric lubricant as shown, to the connectors as hydrolock may result when attempting to mate the connectors. Page 3065 Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 24506 2009 Chevrolet Traverse 2007-2009 GMC Acadia 2007-2009 Saturn OUTLOOK 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood bussed electrical center (UBEC) is located in the engine compartment on the passenger side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. Note Remove the two relays next to the fuse to gain access to the fuse. 4. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Install the two relays removed in Step 4. 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 10. Secure the UBEC cover on the UBEC. 11. Close the hood. 12. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 13. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in Page 7111 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 16180 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 6772 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 9242 Camshaft Position Sensor: Connector Views Engine Controls Connector End Views Camshaft Position (CMP) Sensor Diagrams Ignition Relay: Diagrams Engine Electrical Connector End Views Run Relay (TP2) Run Relay (TP2) Page 16324 For vehicles repaired under warranty, use the table. Disclaimer Page 12970 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 3109 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 5820 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 13285 Disclaimer Page 6192 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 3564 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the appropriate spark plug wire boot(s) (2) from the spark plug. (left side shown, right similar). 1. Twist the spark plug boot 1/2 turn. 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose in order to remove the spark plug wire boot from the spark plug. 2. Loosen the spark plug 1 or 2 turns. (left side shown, right similar). 3. Brush or air blast away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than 1 plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Electrical - Various Rear Door Electrical Malfunctions Fuse: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 6568 4. If installing the old sensor, apply sealant to the threads of the sensor. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 5. Using J 41712, install the sensor. Tighten the sensor to 30 N.m (22 lb ft). 6. Connect the fuel pump/oil pressure sensor electrical connector (3). 7. Check and adjust the engine oil level, if necessary. Page 15626 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 8981 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 6492 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 11939 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 1367 1 - Door Frame 2 - Door Lock Switch - Driver 3 - Speaker - Left Front 4 - Door Latch Assembly Driver Passenger Door (AU3 -AN3/DL3) Page 16477 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness Page 12086 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 8138 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 3879 Page 14747 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 16034 Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 13622 Page 14711 Page 8562 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 2206 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 23103 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 17082 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 2472 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 16329 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 16112 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 20467 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 15609 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 14959 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 4431 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8-11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8-11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kpa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. * Normal The compression builds up quickly and evenly to the specified compression. * Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. * Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Diagrams Ignition Relay: Diagrams Engine Electrical Connector End Views Run Relay (TP2) Run Relay (TP2) Page 7082 Page 6859 Page 8878 Method 1 Method 2 Page 7057 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 7032 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 10937 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 7884 Camshaft Position Sensor: Connector Views Engine Controls Connector End Views Camshaft Position (CMP) Sensor Page 7081 Page 22431 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Retractor: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Locations Crankshaft Position Sensor: Locations Engine Controls Component Views Right Side of Engine 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 9092 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 10508 3. Once installed, pull on both sides of the connection in order to make sure the connection is secure. Page 226 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 5325 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 17136 Fuse Block - I/P X3 Page 15986 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 12663 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 1842 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 15208 Page 6404 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure Page 8623 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 14865 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 7509 Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. ...............................................1,200-1,500 ohms per ft Page 4822 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure Important: Prior to removing the spark plug wire(s) note the correct routing of the wires as required. 1. Remove the appropriate spark plug wire boot(s) (1, 2) from the ignition coil. 1. Twist the spark plug boot 1/2 turn. 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose, in order to remove the spark plug wire boot from the ignition coil. 2. Remove the appropriate spark plug wire boot(s) (2) from the spark plug. (left side shown, right similar). 1. Twist the spark plug boot 1/2 turn. Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Electrical Symbols Electrical Symbols Body - Door Module/Switch Programming Information Door Module: Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Page 9432 Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Diagrams Seat Belt Tensioner: Diagrams SIR Connector End Views Seat Belt Pretensioner - Driver Seat Belt Pretensioner - Passenger Page 21946 For vehicles repaired under warranty, use the table. Disclaimer Page 13767 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 22184 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Page 23155 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 10670 6. Remove the fuel pipe retainer. 7. Pull straight up on the pipe in order to remove the pipe from the fuel meter body. 8. Remove and discard the following components from the fuel meter body: * Fuel seal retainer (1) * Upper fuel seal (2) * Spacer ring (3) * Lower fuel seal (4) Installation Procedure Page 2640 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 4625 4. If equipped with RPO LY6 (6.0L) engine, remove the oil cooler hoses from the clip. 5. Place a jack or utility stands at the rear of the vehicle. 6. If equipped, remove the engine protection shield. Refer to Engine Shield Replacement. 7. For both 1500 and 2500 series, support the front differential carrier with a suitable adjustable jack. 8. For 1500 series vehicles, remove the differential carrier right side nuts. Page 16884 Page 19491 Page 12622 Shift Solenoid: Connector Views 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Electrical - Multiple Electrical Concerns Wiring Harness: Customer Interest Electrical - Multiple Electrical Concerns Bulletin No.: 07-08-49-018 Date: September 07, 2007 TECHNICAL Subject: Various Electrical Concerns - Intermittently Functioning or Inoperative Component, IP Warning Light On, DIC Message Displayed, DTC Set, No Crank/Start (Repair IP Wiring Harness) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on one of the driver notifications and/or effects shown above. Page 8239 Page 603 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 21094 Hood Stop: Service and Repair Hood Stop Bracket Replacement Hood Stop Bracket Replacement Page 4914 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 3725 Notice: Refer to Power Steering Hose Disconnected Notice. 2. Disconnect the power steering fluid cooler hose clamp and hose (3) from the steering gear (2). 3. Remove the power steering gear outlet pipe (1) from the steering gear (2). Installation Procedure 1. Install the power steering gear outlet pipe (1) to the steering gear (2). 2. Connect the power steering fluid cooler hose (3) and hose clamp to the steering gear (2). 3. Clean any excess fluid from the vehicle and remove the drain pans. 4. Fill and bleed the power steering system. Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Page 22401 Page 13151 Transmission Control Module (TCM), Engine Side Page 6786 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 14898 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 10182 Page 16435 X324 Inline Harness Connector End Views X324 Driver Seat Harness to Driver Seat Jumper Harness (AN3) Page 12584 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Hood Bumper Replacement Hood Stop: Service and Repair Hood Bumper Replacement Hood Bumper Replacement Page 15977 Warranty Information (Saab U.S. Models) Disclaimer Page 1918 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14188 15. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3-5 lb in) greater than the rotating torque recorded during removal. 16. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 17. Determine the selective shim thickness for the pinion gear bearing retainer. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Pinion Depth Adjustment (10.5 Inch Axle). 18. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to sealing surface of the pinion gear bearing retainer. 19. Install the selective shim. Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer. 20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to surface of the selective shim. 21. Install the pinion gear bearing retainer. 22. Install the pinion gear bearing retainer bolts. Tighten the pinion gear bearing retainer bolts to 88 N.m (65 lb ft). 23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal. The rotating torque of the pinion and the ring gear should be between 3.9-6.2 N.m (30-55 lb in) for new bearings or 2.8-5.6 N.m (25-50 lb in) for used bearings. 24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary. Page 12235 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2171 Fuel Tank Pressure Sensor: Diagrams Engine Controls Connector End Views Fuel Tank Pressure (FTP) Sensor Page 2986 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Heated Oxygen and Oxygen Sensor Notice Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice Heated Oxygen and Oxygen Sensor Notice Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Specifications Timing Cover: Specifications Engine Front Cover Bolt ...................................................................................................................... ....................................................... 12 N.m 106 lb in Page 4071 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 18029 Notice: Refer to Fastener Notice. Important: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3). Tighten the TORX screw to 1.3 N.m (11.5 lb in). Important: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 1. Apply tire soap to the rubber portion of the valve stem (1). 2. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 22429 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 7209 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pan: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Oil Pan Tighten the bolts alternately and evenly to ............................................................................................................................................ 11 N.m (97 lb in). Page 23813 Disclaimer Page 9840 Page 8120 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. A/C - Control Module A/C Indicator Blinking Control Module HVAC: All Technical Service Bulletins A/C - Control Module A/C Indicator Blinking Bulletin No.: 07-01-38-006 Date: August 20, 2007 INFORMATION Subject: Information For Vehicles with HVAC Control Module A/C Indicator Blinking Due to Low Battery State of Charge Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Manual Temperature Control HVAC System (RPO CJ3) An Air Condition (A/C) button on the Heating, Ventilation and Air Conditioning (HVAC) control module may blink when the A/C system is activated. The blinking indicator will turn to a solid light after cycling the A/C button or ignition key. This condition may be caused by a low battery state of charge on a PREVIOUS ignition key cycle. This condition may be due to situations were an unsold vehicle is parked for long periods of time as part of a dealership's unsold inventory. The A/C indicator begins to flash if the battery voltage falls below 9.5 volts. The low voltage condition may occur during an engine crank or if the vehicle is parked and a normal battery state of charge is not maintained. If the A/C indicator continues to blink, use the Tech 2(R) to help determine the cause. Connect the Tech 2 and build the vehicle. Select Powertrain. Select Engine Control Module (ECM). Select Data Display. Select Cooling/HVAC data. Make sure that there has been an A/C request signal. History should indicate any causes. If necessary, refer to SI for further information on HVAC system diagnostic procedures. Page 11140 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 1048 Engine Control Module X2 (Pin 31 To 73) Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - Step 7 Page 1098 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 14828 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 18036 Spare Tire: Service and Repair Spare Wheel Hoist Replacement Tire Hoist Secondary Latch Mechanism Important: If the spare tire hoist has been fully raised without a spare tire in place, the secondary latch mechanism may have become engaged. If this has occurred the hoist will not lower and the following steps will need to be followed: 1. Rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable (1) is exposed. 2. While holding the latch pin (3), fully depress the latch button (2) and release the secondary latch from the hoist assembly. Some side-to-side and/or up-and-down movement may be necessary to disengage the latch mechanism. 3. Continue rotating the hoist shaft counterclockwise in order to lower the hoist the rest of the way. 4. If this does not release the secondary latch, the spare tire hoist will need to be replaced. See the following procedure. Removal Procedure 1. If the vehicle is equipped with a spare tire stowage lock cylinder, open the spare tire lock cover on the bumper and using the ignition key, remove the lock. Notice: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. Page 20715 For vehicles repaired under warranty, use the table. Disclaimer Page 537 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 20492 Disclaimer Page 2385 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 7355 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 22912 Page 2524 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7984 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 17305 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) (U42) Page 7345 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 7245 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 20638 Note Using the punch and hammer, strike the rounded end of the roll pin to loosen the roll pin. The head of the roll pin should protrude from the handle housing. Remove the roll pin with pliers as shown in the illustration. 3. Using a punch, hammer, and pliers, remove the roll pin from the inside door handle. 4. Discard the roll pin. 5. Install the new roll pin that is included in the door handle kit, P/N 88880051. 6. Install the front side door inside handles. Refer to Front Side Door Inside Handle Replacement in SI. Rear Side Door Inside Handle Replacement 1. Remove the driver and passenger rear side door inside handles. Refer to Rear Side Door Inside Handle Replacement in SI. 2. Place rear side door inside handles on a work bench. Note Using a punch and hammer, strike the rounded end of the roll pin to loosen the roll pin. The head of the roll pin should protrude from the handle housing. Remove the roll pin with pliers as shown in the illustration. 3. Using a punch, hammer, and pliers, remove the roll pin from the inside door handle. 4. Discard the roll pin. Page 13117 Clutch Control Solenoid Valve: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 10131 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections Page 17074 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 2915 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 16606 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 6126 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 1092 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Roof Beacon Relays Hazard Flasher Relay: Diagrams Roof Beacon Relays Power and Grounding Connector End Views Roof Beacon Relay (TRW) Page 9240 Interior - Elimination Of Unwanted Odors Carpet: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 1828 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 4481 3. Tighten the coolant heater bolt until both of the locking wings draw tightly against the inner wall of the engine block. Tighten the bolt to 2 N.m (18 lb in). Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. 4. Connect the heater cord to the coolant heater (4). 5. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 6. Inspect the cooling system for leaks. Page 8925 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 2216 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 13904 Transmission Mount: Service and Repair Allison - Automatic Transmission Transmission Mount Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nut or nuts. 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1). 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle. Installation Procedure 1. Install the transmission mount to the vehicle. Notice: Refer to Fastener Notice. 2. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). Tighten the bolts to 50 N.m (37 lb ft). Page 9535 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 6871 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2991 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21935 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Page 16975 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 18774 1 - Door Frame 2 - Window Switch - Left Rear (ABV) 3 - Speaker - Left Rear Door 4 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 5 - Window Motor - Left Rear (ABV) Right Rear Door (Extended Cab) Page 17094 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 4296 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 22362 For vehicles repaired under warranty, use the table. Disclaimer Page 1972 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 4989 Page 23218 Driver/Vehicle Information Display: Diagrams Object Detection Connector End Views Object Detection Connector End Views Information Center Telltale Assembly Page 24276 Window Switch - Passenger (A31 -AN3/DL3) Window Switch - Right Rear (Crew Cab +A31/Extended Cab +ABV) X100 - X199 Multiple Junction Connector: Diagrams X100 - X199 X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness X103 OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 10623 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 18132 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Air Temperature Sensor Replacement - Lower Left Side Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Left Side Air Temperature Sensor Replacement - Lower Left Side Page 22492 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 11111 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 2786 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 23457 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 21646 Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagrams can be found via their numbers at Vehicle Locations. See: Locations Page 11790 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 8128 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 8953 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 5937 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 10433 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 10133 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 12212 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 6612 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 9855 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 14799 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 11441 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 4721 Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 10. Use the J 38606 if the clearance does not permit use of the J 5892-D. 11. Install the valve stem O-ring seal. 12. Install the valve stem keys. Use grease in order to hold the valve stem keys in place. 13. Carefully release the valve spring pressure, making sure the valve stem keys stay in place. Notice: The valve stem keys must correctly seat in the valve spring cap. Engine damage may occur by not installing properly. 14. Remove the J 5892-D or the J 38606. 1. Look to ensure that the valve stem keys seat properly in the upper groove of the valve stem. 2. Tap the end of the valve stem with a plastic faced hammer in order to seat the valve stem keys, if necessary. 15. Remove the J 22794. 16. Install the spark plugs. 17. Install the valve rocker arms. Page 2328 Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Use the J 43631 to press the stud from the wheel bearing/hub. Installation Procedure 1. Install a new stud. Use washers and a wheel nut and pull the new stud into the hub. 2. Install the brake rotor. 3. Install the tire and wheel. 4. Lower the vehicle. Page 8293 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 154 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 299 11 - Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) 12 - Seat Adjuster Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Page 6730 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11084 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 22382 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 5483 Locations Trunk / Liftgate Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 11411 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 16301 Fuse Block - Underhood X5 Page 12620 Page 9903 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 10439 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 5361 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 13604 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 7613 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 5712 Body Control Module (BCM) X3 Page 1271 Control Module: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (MW7) 1 - Transmission Control Module 2 - Transmission Control Module Connector 3 - Radiator Fan Shroud A/T Controls - DTC P1825/P182E or P1915/MIL ON Shift Cable: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 13150 Control Module: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Control Module (TCM), Engine Side Page 23957 Marker Lamp: Connector Views Lighting Systems Connector End Views Marker Lamp - Left Front (Z88) Marker Lamp - Right Front (Z88) Page 24749 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 9877 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 5706 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 7572 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 9813 Transmission Position Switch/Sensor: Service and Repair Allison - Automatic Transmission Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Page 10480 Fuel Injector: Connector Views Engine Controls Connector End Views Central Sequential Fuel Injection (SFI) X1-X6 Central Sequential Fuel Injection (SFI) X7 Page 15381 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. Page 13774 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 22211 Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with A68) Rear Seat Back Cushion Cover and Pad Replacement (Extended Cab with A68) Page 16471 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X275 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness Page 5313 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 19638 Disclaimer Page 5356 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 7653 Intake Air Temperature Sensor: Diagrams Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 9143 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 18316 7. Remove the evaporator tube nut from the condenser. 8. Disconnect the evaporator tube from the condenser. 9. Remove the insulator retainer bolts and the upper insulator retainers. 10. Remove the condenser from the vehicle. Installation Procedure Important: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities for system capacity information. 1. Install the condenser to the vehicle. Notice: Refer to Fastener Notice. 2. Install the upper insulator retainers and the insulator retainer bolts. Tighten the bolts to 2.4 N.m (21 lb in). 3. Connect the evaporator tube to the condenser using new sealing washers. Refer to Sealing Washer Replacement. 4. Install the evaporator tube nut to the condenser. Tighten the nut to 16 N.m (12 lb ft). 5. Connect the compressor discharge hose to the condenser using new sealing washers. 6. Install the compressor discharge hose nut to the condenser. Tighten the nut to 16 N.m (12 lb ft). Page 216 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 1705 Trailer Brake Control Panel Switch Page 6036 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 11218 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 11903 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 17149 Junction Block - Left I/P X9 Page 14249 15. For those vehicles equipped with RPO code JH6, use the J 45270 (1) to remove the wheel studs (2). 16. For those vehicles equipped with RPO code JH7, use a hydraulic press to remove the wheel studs. 17. Remove the rear brake disc from the rear axle hub. Installation Procedure 1. For vehicles equipped RPO code JH7, position the brake rotor on the rear axle hub. Page 5918 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 22978 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 23617 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 7512 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose in order to remove the spark plug wire boot from the spark plug. 3. Open the spark plug wire separators (1). 4. Remove the appropriate spark plug wire(s). Installation Procedure Notice: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 1. If reinstalling the old spark plug wires, apply dielectric grease GM PN 12345579 (Canadian PN 10953481), or equivalent to the inside the spark plug wire boots. 2. Install the appropriate spark plug wire(s) 3. Close the spark plug wire separators (1). 4. Install the appropriate spark plug wire boot(s) (2) to the spark plug. (left side shown, right similar). Page 2260 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 2363 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 5968 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 23921 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 18038 10. Remove the spare tire hoist shaft guide from the bumper. Installation Procedure 1. Install the spare tire hoist shaft guide to the bumper. 2. Install the hoist to the crossmember. Notice: Refer to Fastener Notice. 3. Install the bolt. Tighten the bolt to 40 N.m (30 lb ft). 4. Install the collar to the hoist 5. Install the shaft to the hoist. Page 21399 Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Left Side (with RPO SLT) Page 6501 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16512 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Important: * Always note the orientation of the relay. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Page 15285 Brake Rotor/Disc: Removal and Replacement Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Caution: Refer to Road Test Caution. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Front Brake Rotor Replacement (JD9, JF3, JF7) Front Brake Rotor Replacement (JD9, JF3, JF7) Page 61 For vehicles repaired under warranty use, the table. Disclaimer Page 13467 Transmission Mode Switch: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Internal Mode Switch (IMS) Internal Mode Switch (IMS) Page 20371 Trailer Brake Control Module: Diagrams Trailer Brake Controller Module (TBCM) Electronic Suspension Control (ESC) Module Page 13167 Automatic Transmission Dipstick - Dipstick Tube: Service and Repair Allison - Automatic Transmission Transmission Fluid Filler Tube and Seal Replacement Removal Procedure 1. The transmission case has provisions that enable the fill tube to be installed on either the right or left side of the transmission. Proceed to step 9 if servicing the plug and/or seal opposite the fill tube. 2. If the vehicle is equipped with a diesel engine, the transmission must be removed to service the fill tube and/or seal. 3. Remove the transmission fluid level indicator. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the heat shield. 6. Remove the fill tube nuts. 7. Place a drain pan under the transmission to catch any dripping fluid. 8. Loosen the fill tube from the transmission. 9. Remove the fill tube and seal from the vehicle. 10. Remove the fill tube plug (1). 11. Remove the fill tube plug seal (2). Installation Procedure 1. Install a new fill tube plug seal (2) into the main housing. 2. Align the tab on the fill tube plug (1) with the tang on the main housing. 3. Install the fill tube plug (1). Press the plug into the seal (2) until the tab on the fill tube plug locks into place in the notch on the main housing. Page 16206 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 11646 Page 5499 Thermostat: Service and Repair Engine Coolant Thermostat Replacement (LU3) Removal Procedure 1. Remove the water outlet tube. 2. Remove the water outlet. 3. Remove the thermostat. 4. Clean the sealing surface of the water outlet. 5. Clean the sealing surface of the intake manifold. 6. Remove and discard the O-ring seal. Installation Procedure 1. Install a NEW O-ring seal to the thermostat. 2. Install the thermostat. Page 885 Body Control Module (BCM) X4 Page 19261 Alarm Module: Diagrams Immobilizer Connector End Views Theft Deterrent Control Module Page 6591 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 12082 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 16133 Page 15223 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Page 9898 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 592 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13420 Page 8361 Accessory Wakeup Serial Data Page 12341 12. Inspect the transmission fluid pressure manual valve position switch assembly for the following conditions: * Damage * Debris * Damaged or missing O-rings * Cracked connector * Loose electrical terminals * Poor terminal retention 13. Remove the manual detent spring bolt. 14. Remove the manual detent spring. 15. Inspect the manual detent spring for cracks or damage. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 16. Remove the remaining valve body bolts. Page 267 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 10895 Page 10483 Fuel Injector 4 Fuel Injector 5 Page 2040 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21742 For vehicles repaired under warranty, use the table. Disclaimer Page 6102 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 16691 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 19705 Page 6698 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (2) from the HO2S pigtail electrical connector (1). 4. Remove the HO2S pigtail electrical connector clip from the engine wiring harness clip (3). 5. Remove the HO2S (3). Page 16022 Page 23131 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9030 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 6027 Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 2658 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Temperature Versus Resistance Page 420 Allison - Automatic Transmission Control Module: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Diagrams Power Window Relay: Diagrams Window Systems Connector End Views Sliding Rear Window Close Relay (A48) Sliding Rear Window Open Relay (A48) Page 6527 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 12919 Shift Solenoid: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Page 22974 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 19984 Audio Amplifier X2 (UQA) Page 11796 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 6665 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 12127 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 21352 Disclaimer Page 9394 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 6597 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13994 ^ Inspect transmission filter for any cracks, holes or split seams that may allow air to be sucked into the pump. ^ Inspect the check balls for roundness ensuring that there are no flat spots. ^ Measure all the valve body bore plugs (328) for diameter. The specification is 11.502 mm +/0.004 mm. Undersize bore plugs should be replaced. ^ Inspect clutch select valve 2 (352) (Closest to the manual valve) in the lower valve body (351) for freedom of movement and travel. ^ Inspect CBR1/ C456 Reg Valve (327) in the upper valve body (321) for freedom of movement and travel. ^ Perform Control Solenoid Valve and Transmission Control Module Assembly Solenoid Performance Test (SI Document ID # 1618572) to determine if shift solenoid # 1 is functioning properly. Important: The seals included in plate kit, P/N 24236934, should be replaced when the valve body is assembled. Do not reuse the old seals. ^ Replace the spacer plate with P/N 24245720. This spacer plate makes use of a revised gasket to help reduce the occurrence of DTC P0751. Page 397 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 17335 Multiple Junction Connector: Diagrams X400 - X499 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X414 Inline Harness Connector End Views X414 Chassis Harness to Camper Harness (UY2/8S3) Page 4689 25. Install the engine wiring harness ground nut and ground wire (1) to the rear of the right cylinder head. Tighten the nut to 16 N.m (12 lb ft). 26. Install the engine wiring harness bracket bolt (1). Tighten the bolt to 12 N.m (106 lb in). 27. Install the EVAP canister tube. Page 23851 HVAC - Automatic Solar Sensor: Locations HVAC - Automatic HVAC Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 14764 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 7147 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 4172 Page 1391 For vehicles repaired under warranty, use the table. Disclaimer Service and Repair Output Yoke: Service and Repair Output Flange/Yoke Replacement Removal Procedure 1. Place the transmission in the Park (P) selector position. Caution: Apply the parking brake and block the drive wheels before performing this procedure in order to prevent bodily injury. 2. Apply the parking brake and chock the wheels to prevent vehicle movement. 3. Remove the vehicle driveline from the transmission yoke assembly (1). Remove the bolt (3) and seal-ring washer (2). 4. Remove the yoke assembly (1). Important: Do the following prior to installation of the yoke assembly: * Be sure the yoke, output shaft and retaining hardware are clean. * Verify the output seal is free of tears or cuts. * DO NOT attempt to remove scratches from the output seal journal on the yoke assembly. Repair may produce machine lead and leakage. Inspect the yoke assembly and replace it whenever there are nicks or scratches on the seal journal or on the lead-in chamfer just ahead of the seal journal. Installation Procedure 1. Lubricate the internal splines and the rear seal journal of the yoke assembly with clean transmission fluid. 2. Install the yoke assembly (1) onto the transmission output shaft. Notice: Refer to Fastener Notice. 3. Install the bolt (3) and seal-ring washer (2). Tighten the bolt to 123 N.m (91 lb ft). 4. Attach the vehicle driveline to the transmission yoke assembly. Refer to Transmission Replacement. 5. Be sure the selector is in the Park (P) position. Page 9131 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Page 5427 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 12187 Page 13148 Transmission Control Module (TCM) 80-Way Connector (Part 1) Page 7477 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 24311 Window Switch - Passenger (A31 -AN3/DL3) Window Switch - Right Rear (Crew Cab +A31/Extended Cab +ABV) Page 16902 Page 15369 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (JD9, JF3, JF7) Allison - Automatic Transmission Transmission Mode Switch: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 7557 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 10910 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 11584 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 14846 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 13588 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 2052 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 12264 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 7606 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 3876 Page 21980 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) Sunroof Motor/Actuator Initialization/Teach Process (Extended Cab New Motor) Perform the Initialization/Teach Procedure any time a new sunroof motor/actuator is installed in the vehicle. 1. Press and hold the open switch until the glass panel stalls at the hard stop, then moves slightly forward. This position is called the soft stop or full open position. 2. Release the switch. 3. Press and hold the open switch within 6 seconds. 4. Hold the open switch until the glass panel moves to the closed position and stops. 5. Release the switch. Diagrams Pedal Positioning Switch: Diagrams Adjustable Pedal Connector End Views I/P Multifunction Switch Assembly Page 17327 X309 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) Page 18658 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 10633 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 3900 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 22261 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Page 13261 21. Remove the spacer plate support bolts (77). 22. Remove the spacer plate support (53). 23. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). Notice: Refer to Fastener Notice. 2. Install the spacer plate support (53) and bolts (77). Tighten the bolts to 10 N.m (89 lb in). Page 9287 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 17387 X414 Chassis Harness to Camper Harness (UY2/8S3) X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Page 24550 Do you have questions? If you have questions or concerns that your dealer/retailer is unable to resolve, please contact the GM Customer Assistance Center. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com. If after contacting your dealer/retailer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 10153 Division Owner Letter Division Owner Letter Page 7338 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11421 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 5292 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23904 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 10700 6. Remove the fuel pipe retainer. 7. Pull straight up on the pipe in order to remove the pipe from the fuel meter body. 8. Remove and discard the following components from the fuel meter body: * Fuel seal retainer (1) * Upper fuel seal (2) * Spacer ring (3) * Lower fuel seal (4) Installation Procedure Page 1642 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 16738 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14218 4. Drive the outer bearing cup into the wheel hub using the J 44419 (2) and the J 8092 (1). Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 5. Install the retaining ring into the groove. Make sure the retaining ring is fully and evenly seated in the groove. 6. Turn the wheel hub over and seat the outer bearing assembly against the retaining ring using the J 24426 (2) and the J 8092 (1). 7. Ensure that the outer bearing assembly rotates freely in the hub. 8. Turn the wheel hub over and install the inner bearing cup. Page 6945 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 4999 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 11404 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 22464 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 11051 View of the connector when released from the component. View of another type of Micro 64 connector. Page 18765 Clockspring Assembly / Spiral Cable: Removal and Replacement Inflatable Restraint Steering Wheel Module Coil Replacement Special Tools J 42640 Steering Column Anti-rotation Pin Removal Procedure Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. 1. Verify the following before removing the inflatable restraint steering wheel module coil: * The wheels on the vehicle are straight ahead. * That anti-rotation pin J 42640 is installed or the ignition and start switch is in the LOCK position. 2. Remove the steering wheel. 3. Remove the steering column shroud. 4. Disconnect any electrical connectors as needed. 5. Remove the inflatable restraint steering wheel module coil retaining ring (2) and discard it. DO NOT reuse the ring. 6. Remove the inflatable restraint steering wheel module coil (1) from the steering shaft. 7. If replacing, discard the old inflatable restraint steering wheel module coil. Installation Procedure Notice: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. Important: Do not remove the centering tab from the new inflatable restraint steering wheel module coil until the installation is complete. If the centering tab is missing then re-center the assembly. 1. If reusing the existing inflatable restraint steering wheel module coil it MUST be centered. Refer to Inflatable Restraint Steering Wheel Module Coil Centering. Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: All Technical Service Bulletins Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 4040 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 2487 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 10936 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 21862 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 9315 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6030 Lighting - Turn Signals Have Increased Flash Rate Body Control Module: Customer Interest Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5429 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 7089 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 2008 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor from the cylinder head. Installation Procedure Notice: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, Page 17488 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Page 15736 10. Position the engine wiring harness terminal (3) against the engine block and position the negative battery cable terminal (1) on top of the engine wiring harness terminal. 11. Install the negative battery cable bolt (2) to the front of the engine block. Tighten the bolt to 25 N.m (18 lb ft). 12. Position the oil pan skid plate and install the bolts, if equipped. Tighten the bolt to 28 N.m (21 lb ft). 13. Lower the vehicle. Page 7797 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 15031 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Connect the internal wiring harness electrical connectors to the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) 23. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 24. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 17101 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 6504 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 19918 Page 12857 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 18766 2. Align the inflatable restraint steering wheel module coil (1) with the horn tower on the turn signal switch cancel cam (2). 3. Slide the inflatable restraint steering wheel module coil (4) onto the steering shaft (2). 4. Firmly seat the new inflatable restraint steering wheel module coil retaining ring (3) into the appropriate groove on the steering shaft (2). 5. Remove and discard the centering tab from the new inflatable restraint steering wheel module coil (4). 6. Connect any electrical connectors as needed. 7. Install the steering column shroud. 8. Install the steering wheel. 9. Remove anti-rotation pin J 42640. Page 1155 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 18488 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 1615 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P C4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Page 259 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 11034 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 4010 Page 1027 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 1535 Page 21161 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 11641 Page 1572 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Rear Wheel Speed Sensor Ring Replacement Tools Required * J 8092 Driver Handle * J 21128 Axle Pinion Oil Seal Installer * J 23690 Bearing Installer * J 2619-01 Slide Hammer * J 45857 Tone Wheel and/or Bearing Remover * J 45860 Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. 3. Remove the rear wheel speed sensor. 4. Remove the rear axle housing cover. 5. Remove the axle shaft. 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J 45857 (1) and the J 2619-01 (2). Installation Procedure 1. Install the wheel speed sensor ring using the J 45860 (1) and the J 8092 (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. Page 7923 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 16472 X276 Inline Harness Connector End Views X276 Steering Column Harness to Inflatable Restraint Steering Wheel Module Coil (KA9) Page 9495 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 14331 Seals and Gaskets: Service and Repair Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Removal Procedure 1. Remove the flange bolts. 2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. 3. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal. 4. Remove the axle shaft from the tube. 5. Remove the gasket. 6. Clean the axle shaft flange and the outside face of the hub assembly. Installation Procedure 1. Install the gasket onto the axle shaft. 2. Install the gasket and the axle shaft into the axle tube. 1. Ensure the shaft splines mesh into the differential side gear. 2. Align the holes in the axle flange and the gasket with the holes in the hub. Notice: Refer to Fastener Notice. 3. Install the axle flange bolts. * For the 10.5 inch axle, tighten the rear axle flange bolts to 156 N.m (115 lb ft). * For the 11.5 inch axle, tighten the rear axle flange bolts to 185 N.m (136 lb ft). 4. Inspect and add axle lubricant to the axle housing, if necessary. Page 12942 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 13164 3. Install a NEW seal to the indicator tube. 4. Install the oil level indicator tube. Notice: Refer to Fastener Notice. 5. Install the indicator tube bolt, if equipped with RPO HP2. Tighten the bolt to 18 N.m (13 lb ft). 6. Install the indicator tube nut. Tighten the nut to 18 N.m (13 lb ft). Page 11554 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 16488 X325 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) Page 22520 Page 7103 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Ignition Lock Cylinder Case Replacement Ignition Lock: Service and Repair Ignition Lock Cylinder Case Replacement Ignition Lock Cylinder Case Replacement Removal Procedure Caution: Refer to SIR Caution. 1. Remove the inflatable restraint steering wheel module coil. 2. Remove the ignition/start switch. 3. Disconnect the park lock cable from the ignition lock cylinder case. 4. Disconnect the passlock and key buzzer from the ignition lock cylinder case. 5. Remove the 3 ignition lock cylinder case screws (2). 6. Remove the ignition lock cylinder case (1) from the vehicle. Installation Procedure Page 21463 Page 1139 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Shift Solenoid Valve State and Gear Ratio Page 12001 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: * Spark plug fouling-Colder plug * Pre-ignition causing spark plug and/or engine damage-Hotter plug 3. Inspect the terminal post (1) for damage. * Inspect for a bent or broken terminal post (1). * Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. 4. Inspect the insulator (2) for flashover, carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: * Inspect the spark plug boot for damage. * Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. 5. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Page 23554 Vehicle Zoning Strategy Truck Zoning Page 17315 X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Electronic Brake Control Module Replacement (JD9, JF3, JF7) Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (JD9, JF3, JF7) Electronic Brake Control Module Replacement (JD9, JF3, JF7) Page 12774 Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 2 (PCS2) Pressure Switch Manifold (PSM) Page 10820 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 8451 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 12747 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 23005 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 15707 Battery Current Sensor: Diagrams Battery Current Sensor (10 Series) Battery Current Sensor (10 Series) Page 23450 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 4793 Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the air cleaner outlet resonator from the MAF/IAT sensor. 3. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. Page 1274 Transmission Control Module (TCM) 80-Way Connector (Part 1) Page 17988 Tire Pressure Sensor: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 9489 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6609 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 5940 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 5996 Rear Bumper Impact Bar Replacement Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Replacement Rear Bumper Impact Bar Replacement Page 14912 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 15953 Page 16959 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 15971 Warranty Information (Saab U.S. Models) Disclaimer Page 9207 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 8972 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 8432 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 15193 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 35589-A. 23. Remove the J 35589-A from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 26. If the brake pedal feels spongy perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed Procedure (Without JL4) Antilock Brake System Automated Bleed Procedure (With JL4). 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - Step 7 Page 6130 Locations Steering Angle Sensor: Locations Antilock Brake System Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch Page 6077 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 5875 Engine Control Module X2 (Pin 1 To 30) Page 19155 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6110 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 192 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 3947 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 6852 Specifications Spark Plug: Specifications Spark Plug Gap.................................................................................................................................... ...........................................................1.5 mm (0.06 in) Spark Plug Torque......................................... ................................................................................................................................................15 N.m (11 lb ft) Page 24710 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 12313 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 1791 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 12484 4. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Tighten the bolt to 11 N.m (97 lb in). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), Page 448 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 15241 Brake Pad: Service and Repair Rear Disc Brake Pads Replacement (JD9) Rear Disc Brake Pads Replacement (JD9) Page 24696 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 11590 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 196 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12218 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 19381 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Page 9674 Page 8551 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 23175 Navigation Software Update Procedure: Use the following procedure to update the Navigation Radio software using the Nav Software Update Disc P/N 25956121 (software version 0B92): This software update can only be used to update the navigation radios specified in this bulletin. DO NOT use this software to update any other vehicle's navigation radio. The Map DVD will be needed to verify the system operation after the software update has been performed. Use the vehicle's existing map DVD. It is recommended to wear latex gloves while performing the software update, to avoid fingerprints on the product and discs. DO NOT stop the engine until all tasks are completed. The software update MUST be performed with the engine RUNNING and the gear position in PARK. If the vehicle is turned off prior to the software update being completed, the process may not work again and a new Navigation Radio may be required. The software update requires using the map DVD slot. The update will not work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Start the engine, with the gear shifter in PARK - wait until the audio or caution screen is displayed after the opening screen. Press the "NAV" hard key. Press "OK" soft key. Press the "MENU" hard key. Press the "NAV" soft key. Press the "MAP DATABASE INFORMATION" soft key. Press the "CHANGE" soft key. The navigation radio automatically ejects the map DVD. Remove the ejected disc. Load the update disc into the slot located behind the display screen by inserting it partially until the system pulls it in. DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. The screen "PREPARING TO LOAD SYSTEM SOFTWARE" will be displayed while the update is loading. The update should take approximately 4 SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 11787 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 13198 7. Cycle the ignition until Drive or Reverse range is attained. Important: Fluid remains in the external circuits and transmission cavities after draining the transmission. 8. Check the transmission fluid level. Page 16059 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Locations Air Flow Meter/Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 4889 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 23944 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 11936 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 2490 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 18618 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Page 10425 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 11447 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 20722 Front Door Panel: Service and Repair Front Side Door Trim Panel Replacement SLT Front Side Door Trim Panel Replacement (SLT) Page 8756 Auxiliary Body Control Module (XBCM) X1 (Export) Page 7629 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 20886 Subject: Squeaky Outside Door Handle (Grease U-Channel of Handle) Models: 2007-2008 Cadillac Escalade, Escalade EXT, Escalade ESV 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Condition Some customers may comment on a squeak noise coming from the door handle as the handle is actuated. Cause This condition may be caused by the pin and the inside of pawl surface making contact with each other, resulting in a squeak noise. Correction DO NOT REPLACE THE DOOR HANDLE. 1. Remove the fasteners to the door handle, leaving the rod to the latch attached. 2. Apply a generous amount of dielectric silicone grease, P/N 12345579 (in Canada, 10953481), as shown in the graphics, into the U-channel of the handle between the pawl and the tower where the gray pin enters through the spring and the pawl. 3. Cycle the handle at least 20 times to work the grease around the pin and to make sure that the squeak has been eliminated. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Page 16834 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 1934 View of the connector when released from the component. View of another type of Micro 64 connector. Page 23919 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 24150 Page 9154 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 12500 Tighten the bolt to 11 N.m (97 lb in). 6. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 9. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 2581 Vehicle Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor (VSS) HVAC - Automatic Low Pressure Sensor / Switch: Diagrams HVAC - Automatic HVAC Connector End Views A/C Low Pressure Switch Reverse Lockout Solenoid Page 14198 1. Install the ring gear to the differential case. Important: The ring gear bolts on the 8.6 inch and the 9.5/9.5LD inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. 2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Notice: Refer to Fastener Notice. 3. Tighten the ring gear bolts, Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. * For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 N.m (89 lb ft). * For the 9.5/9.5LD inch axles, tighten the ring gear bolts in sequence to 140 N.m (103 lb ft). * For the 11.5 inch axle, tighten the ring gear bolts in sequence to 237 N.m (175 lb ft). 4. Install the pinion bearing cups. 5. Determine the selective shim thickness for the pinion gear. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Pinion Depth Adjustment (10.5 Inch Axle). 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing to the pinion. 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations. 10. Install the outer pinion bearing into the axle housing. 11. Install the new pinion oil seal. 12. Install the pinion into the axle housing. 13. Install the pinion yoke. 14. Install the differential assembly. 15. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 16. Lower the vehicle. Page 9027 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 2189 Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Page 22255 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 21208 1. Position the oil skid plate on the frame. 2. Install the oil skid plate mounting bolts. Notice: Refer to Fastener Notice . Tighten the bolts to 28 N.m (21 lb ft). Page 20249 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 10495 31. Obtain J 38500-A (2). Important: Make sure the valve at the bottom of the canister (3) is closed. 32. Remove the canister top and add top engine cleaner GM P/N 1050002 (Canadian P/N 992872) to the canister. 33. Fill the remainder of the canister with regular unleaded gasoline and install the canister top. 34. Suspend J 38500-A from a convenient underhood location. 35. Connect the hose from J 38500-A (1) to the service port on the J 44466-12 (3). Page 4945 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 1746 Headlamp Switch: Service and Repair Headlamp Switch Replacement (without RPO SLT) Headlamp Switch Replacement (without RPO SLT) Page 18039 6. Install the spare tire to the hoist. Notice: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 7. Rotate the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. 8. Remove the safety stands. 9. Lower the vehicle. 10. Install the spare tire stowage lock cylinder. Page 14712 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 5943 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 239 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 22383 For vehicles repaired under warranty, use the table. Disclaimer Page 4652 15. Remove the oil pan bolts and nuts. 16. Remove the oil pan. 17. Remove and discard the oil pan gasket. 18. Clean and inspect the oil pan, if necessary. Refer to Oil Pan Cleaning and Inspection. Installation Procedure Notice: Any time the transmission and the engine oil pan are off of the engine at the same time, install the transmission before the oil pan. This is to allow for the proper oil pan alignment. Failure to achieve the correct oil pan alignment can result in transmission failure. Page 20669 * Park Tilt Mirrors * Smart High Beams Average Fuel Economy Average fuel economy is calculated using the equation: AFE = Distance/Fuel * Distance = The accumulated distance travelled since the last reset of this value * Fuel = The accumulated fuel consumption since the last reset of this value The engine control module (ECM) sends the average fuel economy GMLAN message to the instrument panel cluster (IPC). The value of this mode is retained during ignition OFF and can be changed between English units and metric units by selecting from the driver information center (DIC) options menu. Average Speed Average speed is calculated using the equation: Average Speed = AVS Distance/AVS Time * Distance = The accumulated distance travelled since the last reset of this value * Ignition On = The accumulated ignition on time since the last reset of this value Oil Life Remaining The ECM sends the oil life remaining percentage to the IPC via GMLAN message. The instrument panel cluster receives a GMLAN message indicating the engine oil life remaining. The DIC displays the current percentage of the GM Oil Life System as determined by the ECM. When the oil life remaining percentage drops below 5 percent, the DIC displays CHANGE ENGINE OIL SOON. When the engine oil is changed, reset the GM Oil Life System. Refer to GM Oil Life System Resetting. Fuel Range This message indicates the estimated distance that the vehicle can travel under the current fuel economy and fuel level conditions since the last battery connection to the IPC. Fuel Range is calculated using the equation: Fuel Range = Range Distance/Range Fuel Used. * Range Distance = The accumulated distance travelled since the last reset of this value. * Fuel Used = The accumulated fuel delivered since the last reset of this value The ECM sends the fuel range value to the IPC. The IPC receives a GMLAN message with fuel information. The fuel range value is retained during ignition OFF and can be changed between English and Metric units by accessing the DIC English/Metric menu. The Fuel Range display cannot be reset. LOW is displayed when fuel range is below a predetermined value. Fuel Used The DIC calculates and displays the total amount of fuel used since the last reset operation. You can reset the fuel used mode by depressing and holding the Set/Reset button for more than 3 seconds. The value of this mode is retained during ignition OFF. Instantaneous Fuel Economy (IFE) Instantaneous fuel economy (IFE) is calculated using the equation: IFE = Distance/Fuel Used. * Distance = The accumulated distance travelled for the last 2 seconds * Fuel = The accumulated fuel delivered for the last 2 seconds The IPC receives a GMLAN message from the ECM. The distance information is calculated by the IPC using the vehicle speed information from the ECM. These values are retained during ignition OFF and can be changed between English and Metric units accessing the DIC English/Metric menu. The IFE display cannot be reset. Tire Pressure Monitor The IPC receives a GMLAN message from the tire pressure monitoring (TPM) system for front and rear tire pressure data. The DIC will display the pressure for each of the front and rear tires. When a tire with low air pressure is present, the DIC displays XXXX XXXX TIRE PRESSURE LOW. Trip Time The timer records elapsed time starting from activation. When the DIC displays the timer, pressing the Set/Reset switch for 1 second on the DIC resets the timer. Pressing the Set/Reset button on the DIC switch for approximately 1 second starts and stops the timer. The DIC displays the timer in one of the following formats: Brakes - Rotor/Drum Refinishing Labor Operations Brake Drum: Technical Service Bulletins Brakes - Rotor/Drum Refinishing Labor Operations Bulletin No.: 06-05-22-007 Date: November 30, 2006 WARRANTY ADMINISTRATION Subject: Brake Rotor/Drum Refinishing Labor Operations Models: 2005-2007 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X (Canada Only) The purpose of this bulletin is to advise dealership personnel of labor operation changes relating to brake repairs. Existing brake rotor and drum labor operations have been revised to remove the refinishing times and new labor operations have been established for refinishing brake rotors or drums. The changes will become effective with the release of the December 2006 Labor Time Guide. The following changes: Applies to all 2005-2007 vehicles, unless 2005 was the last year of production for that particular model. May apply to 2004 and prior models years if the vehicle was produced after 2005 - e.g. TrailBlazer, Envoy, etc. Where the new labor operations for refinishing rotors or drums do not apply, the existing labor operations will still contain time for refinishing. Always refer to the Labor Time Guide for the appropriate labor operations and time for the vehicle being repaired. Page 2530 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 8461 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 13395 Disclaimer Service Precautions Valve Spring: Service Precautions Valve Springs Can Be Tightly Compressed Caution Caution: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Page 8587 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 21627 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 7816 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 21947 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Page 17574 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 8793 Disclaimer Page 1966 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 15818 Page 8271 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 6037 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Locations Entertainment System Control Module: Locations Entertainment/Communication Component Views Headliner and Overhead Console (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infrared Module (U42) 4 - Emergency Vehicle Wiring Blunt Cuts (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Page 22423 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 14041 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Page 11894 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 11261 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 11105 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 24313 Page 15079 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement. Page 3787 2. For the 9.5/9.5LD and the 10.5 inch axles, remove the rear axle fill plug. 3. For the 11.5 inch axle, remove the fill plug. 4. Remove the rear axle drain plug. 5. Drain the lubricant into a suitable container. 6. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. 7. Clean the drain plug. Installation Procedure Notice: Refer to Fastener Notice. 1. Install the rear axle drain plug. Tighten the rear axle drain plug to 33 N.m (24 lb ft). 2. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. Page 10453 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9737 View of the connector when released from the component. View of another type of Micro 64 connector. Page 11962 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 10761 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test Circuit/System Verification Important: On the scan tool, the powertrain relay is referred to as the EC ignition relay. 1. Ignition ON, engine OFF, command the powertrain relay ON and OFF several times using the scan tool output control function. You should either hear or feel the relay click with each command. 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate on at least one test point of each fuse. ‹› If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data list. Circuit/System Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit and ground. ‹› If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 3. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 4. Verify that a test lamp illuminates between the relay coil B+ and ground. ‹› If the test lamp does not illuminate, test the relay coil B+ circuit for a short to ground or an open/high resistance. 5. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground or an open/high resistance. If the circuits test normal Page 9345 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 18151 Page 13246 Fluid Pan: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement Page 23142 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 2024 Page 4115 Page 12097 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 21127 Page 5954 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 5001 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 15851 Vehicle Zoning Strategy Truck Zoning Page 16459 X205 Inline Harness Connector End Views X205 Brake Clutch Harness to Instrument Panel Harness Page 6065 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 3872 Locations Coolant Level Sensor: Locations Cooling System Component Views Left Front of Engine Compartment (Diesel) 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Page 9509 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 2578 Vehicle Speed Sensor: Locations Power Take-Off Power Take-Off (PTO) Component Views Front Frame Rail 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor 4 - Automatic Transmission Input Shaft Speed (AT ISS) Sensor 5 - Automatic Transmission 6 - Vehicle Speed Sensor (VSS) 7 - X124 8 - Power Take Off (PTO) Module 9 - X175 Page 14803 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Service and Repair Camshaft: Service and Repair Camshaft Replacement Removal Procedure 1. Remove the radiator. 2. Remove the air conditioning (A/C) condenser. 3. Remove the lifters. 4. Remove the timing chain and the camshaft sprocket. 5. Remove the balance shaft drive gear. 6. Remove the camshaft retainer bolts and retainer. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 7. Remove the engine camshaft. 1. Install the three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes. 2. Using the bolts as a handle, carefully rotate and pull the engine camshaft out of the camshaft bearings. 3. Remove the bolts from the front of the engine camshaft. 4. Clean and inspect the camshaft and/or bearings, if necessary. Refer to Camshaft and Bearings Cleaning and Inspection. Installation Procedure Page 7997 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 24728 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 5935 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 9058 View of the connector when released from the component. View of another type of Micro 64 connector. Page 19913 Page 3050 4. Connect the engine wiring harness electrical connector (4) to the CKP sensor. 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. 7. Perform the crankshaft position system variation learn procedure. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 21696 Passenger Door Switch (PDS) X3 (AN3/DL3) Page 10884 Accelerator Pedal Position Sensor: Diagrams Engine Controls Connector End Views Accelerator Pedal Position (APP) Sensor Page 7934 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 15733 9. Remove the forward lamp wiring harness ground bolt (1). 10. Remove the forward lamp wiring harness terminal (2) from the frame. 11. Remove the negative battery cable terminal (3) out through the opening between the radiator support and frame. 12. Remove the negative battery cable clip (1) from the chassis harness. 13. Lower the vehicle. 14. Remove the negative battery cable clip (2) from the right wheelhouse liner. Page 5868 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 5368 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 2502 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 15903 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 10691 4. Inspect for fuel leaks. Page 5118 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 19987 Amplifier: Service and Repair Radio Speaker Amplifier Replacement Page 6271 Page 2636 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 10201 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 16401 Multiple Junction Connector: Diagrams X200 - X299 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Locations Daytime Running Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 10941 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Interior - Sun Visor Fails to Stay In Up Position Sun Visor: Customer Interest Interior - Sun Visor Fails to Stay In Up Position TECHNICAL Bulletin No.: 09-08-110-013A Date: April 18, 2011 Subject: Sunshade (Sun Visor) Fails to Stay In Position (Re-seat Detent Spring) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to include the 2012 model year. Please discard Corporate Bulletin Number 09-08-110-013 (Section 08 - Body and Accessories). Condition Some customers may comment that the front sunshade (sun visor) doesn't stay in position tightly against the headliner when in the up position and clipped into the center mount. Cause The condition may be caused by the sunshade being over extended (forced) along the slide on rod to the end of its travel. This over extension can cause the detent spring to be pulled off of the flat on the slide on rod and can cause the detent function to be inoperative. Correction In many cases, the detent spring can be re-seated into the correct position. Use the following procedure to correct the condition. 1. Position the sunshade in the forward position and engage the sunshade into the center clip. Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Page 6018 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Notice: Refer to Fastener Notice. 2. Install the accelerator pedal bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: Page 645 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 9112 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 9053 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Service and Repair Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement The Traction Control Switch is part of the Accessory Switch Assembly. To replace the Traction Control Switch please refer to Accessory Switch Replacement (without RPO SLT) Accessory Switch Replacement (with RPO SLT). Page 5341 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 17300 X202 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Page 21376 Carpet: Service and Repair Body Rear Inner Panel Carpet Replacement Body Rear Inner Panel Carpet Replacement Page 18428 Control Module HVAC: Locations HVAC - Manual HVAC Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 12058 Page 17959 Page 384 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 2543 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 4520 3. Remove the air cleaner adapter nut. 4. In order to remove the air cleaner outlet duct, pivot the duct upward until the hinge clip releases from the lip on the throttle body. 5. Remove the heater outlet hose from the clip. 6. Move and secure the heater hoses out of the way. Page 10027 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 18211 Mode Actuator Replacement Mode Actuator Replacement Page 5097 Page 11018 Throttle Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 20352 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 9175 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 6953 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 1156 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 6471 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 8170 Page 6441 Page 2278 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 8342 Page 7700 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12159 Page 9436 Page 3149 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 17650 Tire Pressure Sensor: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 2400 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 9212 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 24109 6. Remove 100 mm (3.9 in) of harness tape, starting from the back of the connector, to make the repair. 7. Locate and remove the 240 circuit (red wire with white stripe) (1) from cavity E2. 8. Cut off the terminal. 9. Locate circuit 3040 (red wire with a white stripe) (2) located in cavity D1 of connector X1 and cut the 240 and 3040 wires 75 mm (3 in) from the back of the connector. Strip the ends of the wires. OnStar(R) - Availability for Hearing Impaired Navigation System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 5065 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Specifications Compression Check: Specifications No cylinder should read less than .............................................................................................................................................................. 690 kpa (100 psi) Page 23632 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 9568 Page 14819 from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. * The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. 4. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. Notice: Refer to Fastener Notice. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). Tighten the bolts to 12 N.m (108 lb in). Page 24019 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Page 13225 Important: * Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. * Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. * Ensure the following procedures are performed when installing the new retaining rings onto the fittings. Install a new retaining ring into the quick connect fitting using the following procedure: 1. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 2. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 3. Do not install the new retaining ring onto the fitting by pushing the retaining ring. Page 12163 Shift Solenoid 1 (SS1) Shift Solenoid 2 (SS2) Page 11763 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 11042 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 7635 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 5267 Page 11208 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 5528 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Side Exhaust Manifold Replacement - Right Side (4.3L) Removal Procedure 1. Remove the heated oxygen sensor (HO2S). 2. Remove the catalytic converter to exhaust manifold nuts (1). 3. Lower the vehicle. 4. Remove the exhaust manifold heat shield bolts and shield. 5. Remove the spark plugs. 6. Reposition the spark plug wires out of the way, if necessary. Page 7164 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 8446 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 10186 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 17227 Disclaimer Page 13224 3. Install the engine protection shield. 4. Lower the vehicle. 5. Install the transmission fluid cooler hose to the radiator. 6. Install the transmission fluid cooler hose to the Auxiliary oil cooler. 7. Install the front grill assembly. Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Removal Procedure Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Page 14017 Chips or debris plugging the bleed orifice of the 2-3 shift solenoid (367). This will cause the transmission to stay in 2nd gear when 3rd gear is commanded and return to 1st gear when 4th gear is commanded. A 2-3 shift valve (368) or 2-3 shuttle valve (369) that is stuck, restricted and/or hung-up in its bore. This condition may also be an indication of a damaged 2-4 band or 3-4 clutches. This clutch damage may generate debris causing the 2-3 shift valve line-up to stick in the valve body bore and set DTC P0757. Correction Inspect the condition of the transmission fluid for signs of overheat or a burnt odor. If either is noted, the transmission should be disassembled for further investigation and repaired as needed. Inspect the inside of the oil pan for signs of clutch friction material. A small amount of friction material in the bottom of the pan is normal. If a large amount of clutch material is noted in the fluid or bottom pan, the transmission should be disassembled for further investigation and repaired as needed. Inspect and clean the 2-3 shift valve (368), the 2-3 shuttle valve (369) and the valve bore of debris/metal chips. Inspect and clean the 2-3 shift solenoid (367B) opening of debris/metal chips. While inspecting the 2-3 shift solenoid (367B), look for a screen over the solenoid opening. If the solenoid DOES NOT have a screen, replace the solenoid. All current GMSPO stock shift solenoids have a screen over the solenoid opening. If clutch debris is found, it is also very important to inspect the pressure control (PC) solenoid valve fluid screens. Clean or replace the PC solenoid as necessary. It is also important to flush and flow check the transmission oil cooler using J 45096. Refer to SI "Automatic Transmission Oil Cooler Flushing and Flow Test" for the procedure. Refer to the appropriate Service Manual for additional diagnostic information and service procedures. Warranty Information For repairs performed under warranty, use the applicable published labor code and information. Disclaimer Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 7323 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 21283 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 4011 Page 18689 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra, currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. Your vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Your satisfaction with your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will remove the acoustical padding above the SDM. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. Page 16035 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 9605 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 5436 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 7230 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 10082 Canister Vent Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Valve Replacement (Regular Cab w/34 Gal Tank) Evaporative Emission Canister Vent Solenoid Valve Replacement (Regular Cab w/34 Gal Tank) Removal Procedure Important: Clean the evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the fittings in order to avoid possible system contamination. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove EVAP canister vent solenoid clip (1) from the chassis EVAP line. 3. Remove the EVAP canister vent solenoid pipe from the clip (2) on the chassis EVAP line. 4. Remove the EVAP canister vent solenoid pipe from the clips (3) on the brake pipes. 5. Disconnect the chassis wiring harness electrical connector from the EVAP canister vent solenoid. Page 2619 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7710 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 22206 Page 16644 Inspect how the IP branch to C202 is routed. Reroute the wiring as necessary to match the correct routing in the photo above. In order to route the IP harness branch correctly (behind the junction block-left I/P): Remove the cover from the junction block-left I/P, unseat the junction block from the bracket. Disconnect C202. Route the harness such that it lays between the goalposts of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. Make sure that the grey offset retaining clip (off of the IP branch going to C202) is seated into the hole in the dashmat or into the brown buddy clip (if present), securing the IP branch to the vehicle. If the harness is still in contact with a sharp edge or point of the park brake assembly, protect the harness by routing it away from the contact point and holding it there with tie straps, and/or covering the sharp edge with butyl tape. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14547 Transmission Control Module (TCM) 80-Way Connector (Part 1) Page 16254 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 21543 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 11807 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 1643 Solar Sensor: Diagrams HVAC Connector End Views Ambient Light/Sunload Sensor Assembly Page 22661 Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement (w/o KB6) Page 21187 Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Page 15922 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 16184 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 16227 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 21614 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 12586 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 8969 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 17173 Page 18347 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 24514 use of any similar HWFS products that may be sold by aftermarket suppliers. Even though you have declined to have this safety recall performed on your vehicle, please be advised that if you change your mind, your GM dealer will always be available to remove the HWFS from your vehicle and provide reimbursement according to the terms described in the recall notification letter. As part of this declination process, your dealer will ask you to document your refusal to have Safety Recall 10153 performed on your vehicle by signing a Repair Order stating "customer declined recall repair". You will be given a copy of this document for your records. Of course, your signature is voluntary but doing so will help prevent the mailing of recall reminder notices to you as the current owner of record. If you sell this vehicle, you should advise the buyer that this safety recall was not performed on the vehicle and that the recall repair is still available. This notice should also be placed in the glove box so that a future owner of this vehicle will be aware of this safety recall. Page 24281 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 22391 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 14548 Transmission Control Module (TCM) 80-Way Connector (Part 2) Page 5221 9. Engage the radiator inlet hose clip (2) at the fan shroud. 10. Connect upper radiator hose from radiator. 11. Install air inlet duct. 12. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill) Page 13657 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 15904 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 9348 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 11922 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 18054 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 8628 Page 2435 Oxygen Sensor: Service Precautions Excessive Force and Oxygen Sensor Notice Excessive Force and Oxygen Sensor Notice Notice: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. Page 15009 Control Module: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Page 16458 X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) (+U42) Page 989 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 1858 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 23918 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 6635 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 17140 Junction Block - Left I/P X1 Page 7586 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 2394 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7090 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 9113 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 18687 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History screen (dealers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure 1. If the vehicle is equipped with vinyl flooring and no cutout flap under the driver's seat, no further action is required. For all other vehicles, proceed to Step 2. Note Driver seat removal is NOT required for crew cab or extended cab vehicles. Certain 2009 regular cab vehicles built after approximately March 1, 2009 with carpet that has a 2-sided cutout over the SDM, however, will require driver seat removal. Refer to Front Seat Replacement-Bucket in SI. After the seat removal, proceed to Step 2 in the bulletin. Regular cab vehicles with carpet that has a 3-sided cut over the SDM do NOT require seat removal. Page 14393 Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 4. Remove the bolts (6) and the yoke retainers (7) from the front axle pinion yoke (1). Important: Do not drop the bearing cap assemblies of the yoke end. 5. Disconnect the propeller shaft (2) from the front axle pinion yoke (1). Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. 6. Use tape to secure the bearing caps. Page 22336 Page 21224 Page 22952 View of the connector when released from the component. View of another type of Micro 64 connector. Page 3044 Page 15352 Brake Caliper: Overhaul Front Brake Caliper Overhaul (JH6, JH7) Front Brake Caliper Overhaul (JH6, JH7) Caution: Refer to Brake Dust Caution. Caution: Refer to Brake Fluid Irritant Caution. Disassembly Procedure 1. Remove the brake caliper. Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury. Important: The brake calipers use phenolic pistons that have stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Page 10634 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 10264 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 10095 4. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 N.m (80 lb in). 5. Install the fuel/EVAP line clip nut (2). Tighten the nut to 20 N.m (15 lb ft). 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. 9. If equipped with 2WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle. 10. Install the fuel/EVAP line bracket locator tab to the frame. 11. Install the fuel/EVAP line clips to the frame and crossmember. 12. Install the fuel/EVAP line bracket bolt (2). Tighten the bolt to 9 N.m (80 lb in). 13. Install the fuel/EVAP line clip nut (1). Tighten the nut to 20 N.m (15 lb ft). 14. Remove the caps from the fuel and EVAP lines. 15. Connect the fuel tank EVAP line quick connect fitting to the chassis line. 16. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Page 16825 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14630 Transmission Speed Sensor: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Input and Output Speed Sensor (ISS/OSS) Page 16061 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 16360 The concern must be current before diagnosis can be performed. Review and print the following SI documents - Electrical Center Identification Views, for use during diagnosis: - Junction Block - Right I/P, Top View - Junction Block - Right I/P X4 - Junction Block - Right I/P X5 Locate the Junction Block - Right Side IP on the vehicle. For the appropriate actuator, measure the following signals for voltage/resistance from the BACK of the X4 or X5 connector and record the following: DO NOT unplug the X4/X5 connector. Turn Ignition On, A/C Blower Full, if possible - mode on "panel" and Temp to "cold." Once the fault is removed, the actuator will stay in default position until commanded to a new position. Change commanded position regularly to see if the issue is still current. Continue to monitor door positions (feedback) on Tech2 to see if it changes during circuit testing. - Ignition Voltage - 12V - Door Control Signal - 2.5V when stationary, OV when commanded toward "cold" or "panel", 5V when commanded toward "hot" or "defrost" - Low Reference - less than 40 ohm with ignition on. Less than 10 ohm with ignition off - Door Position Signal - measure voltage - 5 Volt Reference - 5V If any signals do not display the correct value or if the issue is corrected during testing, pull the connector and check the terminal for poor tension (use the appropriate terminal tool). Replace or repair the terminal if poor tension is found. If all signals are correct at RH BEC, reconfirm the customer's comments. If the condition is not present, no further repairs are necessary. If the condition is still present, recheck the actuator connector 5 volt reference circuit, pin drag test and repair connector/pin as necessary. Warranty Information For vehicles repaired under Enqineerinq direction, use the table. Headlamp Switch Replacement (with RPO SLT) Headlamp Switch: Service and Repair Headlamp Switch Replacement (with RPO SLT) Headlamp Switch Replacement (with RPO SLT) Page 10938 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 4063 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 12060 Page 8316 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 5879 5. Disengage the retainer tabs securing the ECM to the bracket. 6. Remove the ECM. Installation Procedure 1. Install the bottom ECM tabs into the bracket. 2. Push the ECM in securing the ECM to the bracket. Page 15418 Page 9707 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 8238 Page 5055 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 4612 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 15351 Page 1091 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 3199 Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Crew Cab +ASF) Page 24204 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 16279 Junction Block - Left I/P X13 (AN3) A/T - Torque Converter Replacement Information Torque Converter: All Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Page 22411 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 4163 Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Bracket Replacement Underhood Electrical Center or Junction Block Bracket Replacement Page 6664 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 11402 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 8258 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 11653 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 11612 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 21046 Rear Door Window Motor: Service and Repair Rear Sliding Window Module Replacement Rear Sliding Window Module Replacement Removal Procedure Important: The new rear sliding window motor/module is equipped with the bracket and relays. 1. Remove the rear sliding window lower garnish molding. 2. Cycle the rear sliding window to the fully closed position. 3. Remove the screw (1) from the rear sliding window regulator and cables (2). 4. Pull forward on the regulator and cables (2) to release it from the motor/module. 5. Remove the rear sliding window motor/module nuts (2). Page 19515 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2521 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 9896 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 23585 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 14299 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. Notice: Refer to Fastener Notice. 16. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 N.m (100 lb ft). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Page 5445 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 16157 Page 11889 Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Page 14193 Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Notice: Refer to Fastener Notice. 4. Tighten the new ring gear bolts. Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence to 165 N.m (122 lb ft). 5. Install the pinion and the pinion bearings. 6. Install the pinion gear bearing retainer. 7. Install the differential assembly. 8. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 9. Lower the vehicle. Page 20765 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Extended Cab) Front Door Opening Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Remove the front and rear door sill plate. Refer to Front Side Door Sill Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Plate Replacement (Extended Cab) or Rear Side Door Sill Plate Replacement (Extended Cab) Rear Side Door Sill Plate Replacement (Crew Cab) . 2. Remove the weatherstrip (1) from the pinch-weld flange (2). Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. Page 5277 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 8147 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 22082 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Page 2327 Page 17058 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 14812 Shift Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams 6L50/6L80/6L90 - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Page 3722 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Install drain pans under the vehicle as needed. Notice: Refer to Power Steering Hose Disconnected Notice. Important: Note the routing of the power steering gear inlet hose before removal. It MUST be routed correctly upon installation. 2. Remove the power steering gear inlet hose (2) from the power brake booster (1). 3. Remove the power steering gear inlet hose (2) from the power steering gear. 4. Remove the power steering gear inlet hose (2) from the vehicle. Installation Procedure Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Page 6988 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14768 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. A/C - Blower Motor is Inoperative Blower Motor: All Technical Service Bulletins A/C - Blower Motor is Inoperative TECHNICAL Bulletin No.: 08-01-38-002 Date: April 10, 2008 Subject: Blower Motor Inoperative (Replace Blower Motor) Models: 2007-2008 Chevrolet Silverado Extended and Crew Cab Models Only 2007-2008 GMC Sierra Extended and Crew Cab Models Only with Electronic Temperature Control HVAC System (RPO C67) Built Prior to 4/01/08 Condition Some customers may comment that the blower motor is inoperative. Correction Technicians are to replace the blower motor. The new blower motor assembly P/N 25973845 contains a new moisture shield. Refer to Blower Motor Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12934 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Volume Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Page 18207 Recirculation Actuator Replacement Recirculation Actuator Replacement Interior - Front Seat Armrest Bolt Accessory Cover Arm Rest: All Technical Service Bulletins Interior - Front Seat Armrest Bolt Accessory Cover Bulletin No.: 07-08-50-014 Date: June 20, 2007 INFORMATION Subject: Front Center Seat Armrest Bolt Accessory Cover Available for Service Use Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Driver and Passenger Front Seat Split, Full Feature Center (RPO AZ3) The front center seat armrest bolt accessory cover is now available for service as a separate part. The front center seat armrest bolt accessory cover was formerly available as part of the entire front center seat assembly. DO NOT replace the entire front center seat assembly. If the front center seat armrest bolt finish cover (1) is required, use the following steps below: Open the passenger door. Position the passenger front seat track all the way back. Tilt the passenger seat back to the full tilt back position. Remove the right front center seat armrest hinge cover plastic retainer with a door trim tool. Use a screwdriver to release the inner tabs inside the right front center seat armrest hinge finish cover. Remove the right front center seat armrest hinge finish cover. Pull outward on the front portion of the center seat armrest bolt accessory cover to release the metal retaining clip. Remove the front center seat armrest bolt accessory cover. Remove the metal clip from the old center seat armrest bolt accessory cover. Install the metal clip onto the new front center seat armrest bolt accessory cover. Install the new front center seat armrest bolt accessory cover to the armrest assembly and firmly seat the metal clip. Install the right front center seat armrest hinge finish cover. Install the plastic retainer. Tilt the passenger seat back to the up position. Page 17819 Rack & Pinion Steering Linkage Outer Tie Rod Replacement Page 13702 Page 15950 Electrical - 'No Trailer Connected' Message On DIC Trailer Brake Control Module: All Technical Service Bulletins Electrical - 'No Trailer Connected' Message On DIC TECHNICAL Bulletin No.: 09-05-22-004 Date: November 05, 2009 Subject: No "Trailer Connected" Message on Driver Information Center (DIC) at Startup When Trailer is Connected (Reprogram ITBCM) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Equipped with Integrated Trailer Brake (RPO JL1) Condition Some customers may comment that when they connect their trailer, with the engine off, and after they start the engine, the Trailer Connected message is not displayed on the DIC. With the engine running, if the trailer connector is cycled, the vehicle will detect the trailer and display Trailer Connected. This concern should only affect trailers equipped with trailer brakes on a single axle. Cause The trailer brake control system is only compatible with trailers equipped with electric trailer brakes. The system will not work or detect trailers equipped with any other types of brakes such as surge, air or electric-over-hydraulic trailer brake systems. When a trailer is connected, the Trailer Brake Control Module (TBCM) performs a test to determine if the trailer is equipped with electric trailer brakes. If the trailer wiring or electric trailer brake magnets have additional resistance (caused by poor connections, corrosion, improper splices, etc.), the TBCM may not be able to detect the trailer. Correction A revised calibration has been developed to address these issues. Reprogram the Integrated Trailer Brake Control Module (ITBCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Refer to Trailer Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 11210 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13842 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 11895 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 6921 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 13609 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9653 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 14603 Transmission Mode Switch: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Internal Mode Switch (IMS) Internal Mode Switch (IMS) Page 356 Electronic Brake Control Module (JF3/JF7) A/T - Control Valve/Solenoid Cleaning Information Valve Body: All Technical Service Bulletins A/T - Control Valve/Solenoid Cleaning Information INFORMATION Bulletin No.: 07-07-30-006B Date: March 02, 2010 Subject: Information on Control Solenoid Valve and Transmission Control Solenoid Module Assembly Cleaning Procedure for Rear Wheel Drive Six-Speed HYDRA-MATIC(R) Automatic Transmissions when MIL/DTCs Set Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 Equipped with Six Speed HYDRA-MATIC(R) 6L50, 6L80 or 6L90 Automatic Transmission (RPOs MYB, MYC, MYD) Supercede: This bulletin is being updated to add models and model years and to advise technicians that the control solenoid valve assembly cleaning procedure is no longer valid. Please discard Corporate Bulletin Number 07-07-30-006A (Section 07 - Transmission/Transaxle). The control solenoid (w/body and TCM) valve assembly cleaning procedure has been determined to be ineffective. This procedure will be removed from the scan tool and will be no longer available for use. Reference to this procedure will be removed from SI diagnostics and labor operation K9450 will be removed from the Labor Time Guide. Disclaimer Page 2959 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Service and Repair Power Take-Off Switch: Service and Repair Power Take-Off Switch Replacement Page 16292 Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Top View - Gas Fuse Block - Underhood, Bottom View Page 23866 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 1480 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 6371 Page 17097 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 21494 Sun Visor: Service and Repair Sunshade Replacement Sunshade Replacement Page 4088 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 6991 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9689 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (2) from the HO2S pigtail electrical connector (1). 4. Remove the HO2S pigtail electrical connector clip from the engine wiring harness clip (3). 5. Remove the HO2S (3). Page 23820 6. Remove 100 mm (3.9 in) of harness tape, starting from the back of the connector, to make the repair. 7. Locate and remove the 240 circuit (red wire with white stripe) (1) from cavity E2. 8. Cut off the terminal. 9. Locate circuit 3040 (red wire with a white stripe) (2) located in cavity D1 of connector X1 and cut the 240 and 3040 wires 75 mm (3 in) from the back of the connector. Strip the ends of the wires. Page 10142 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Notice: Refer to Fastener Notice. 2. Install the accelerator pedal bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: Page 9769 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 18670 * Remove the SIR coil from the steering column and allow the coil to hang freely before the shaft is rotated. Refer to Inflatable Restraint Steering Wheel Module Coil Replacement. * Visually inspect the steering shaft for sheared injected plastic (1). If the steering shaft shows sheared plastic, replace the steering shaft. * Inspect the steering shaft runout for any frame damage that could cause a bent steering shaft. Using a dial indicator at the lower end of the steering shaft, rotate the steering wheel. The runout must not exceed 1.60 mm (0.0625 in). Page 16707 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 228 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12835 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 710 Control Module HVAC: Diagrams HVAC Connector End Views Blower Motor Control Module X1 Blower Motor Control Module X2 Page 6304 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 16412 X211 Instrument Panel Harness (Y91) Or I/P Extension Harness (-Y91) To Console Harness (Y91/UQA/D07) (Pin A1 To C6) Page 9538 Knock Sensor: Connector Views Engine Controls Connector End Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Page 6040 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 8198 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 8487 Page 10812 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Sensor: All Technical Service Bulletins SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 15682 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 12104 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 5114 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 7297 Page 10440 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 17588 Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Diagrams Fuel Gauge Sender: Diagrams Displays and Gages Connector End Views Fuel Pump and Sender Assembly - Front (Gas) Fuel Pump and Sender Assembly - Rear (Gas +LY6) Page 9586 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 15174 Page 4961 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 1192 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 2477 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Lighting - Turn Signals Have Increased Flash Rate Body Control Module: All Technical Service Bulletins Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8404 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 7661 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Page 12523 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 21189 Cross-Member: Service and Repair Transmission Support Crossmember Replacement (2WD 1500/2500) Transmission Support Crossmember Replacement (2WD 1500/2500) Page 4123 Junction Block - Left I/P X1 (Pin A1 To M1) Page 5718 Auxiliary Body Control Module (XBCM) X1 (Export) Page 13390 For vehicles repaired under warranty, use the table. Disclaimer Page 10982 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 6491 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 22314 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 363 Page 4039 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 11361 Crankshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 238 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 1542 Parking Brake Warning Switch: Diagrams Park Brake Switch Park Brake Switch Page 1112 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 7062 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 11334 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 22926 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 2356 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 2032 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Electrical - Various Rear Door Electrical Malfunctions Fuse: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Specifications Idle Speed: Specifications Information not supplied by the manufacturer Page 15788 6. Remove the heater outlet hose clamp bolt (1) at the generator bracket. 7. Disconnect the engine wiring harness electrical connector (5) from the generator. 8. Reposition the engine wiring harness boot (6). 9. Remove the engine wiring harness nut (3) from the generator. 10. Remove the engine wiring harness lead (4) from the generator stud. Page 7153 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Locations Oxygen Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 2142 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Specifications Flex Plate: Specifications Flywheel to Torque Converter Bolt .............................................................................................................................................................. 60 Nm (44 lb ft) Page 13793 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 1207 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular Cab +10 Series +ASF) Page 5151 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 17881 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Page 4823 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose in order to remove the spark plug wire boot from the spark plug. 3. Open the spark plug wire separators (1). 4. Remove the appropriate spark plug wire(s). Installation Procedure Notice: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 1. If reinstalling the old spark plug wires, apply dielectric grease GM PN 12345579 (Canadian PN 10953481), or equivalent to the inside the spark plug wire boots. 2. Install the appropriate spark plug wire(s) 3. Close the spark plug wire separators (1). 4. Install the appropriate spark plug wire boot(s) (2) to the spark plug. (left side shown, right similar). Page 2932 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Caution Caution: Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 2985 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 9612 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 12337 Fluid Pressure Sensor/Switch: Diagrams Automatic Transmission Internal Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Page 5857 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 14766 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 22571 Important: You may directly apply 16 volts to the vertical motor terminals to unlock the lead tilt adjuster screw from the stop. Refer to Power Seat Connector End Views in SI. ^ If the rear vertical motor is locked, tap the end of the seat track bracket (1) while toggling the rear of the seat switch up and down with the aid of an assistant. ^ If the front vertical motor is locked, tap the front of the seat track bracket (1) while toggling the front seat switch up and down with the aid of an assistant. 5. Move the front seat to the full forward position. 6. Position the rear of the seat halfway up to gain access to the rear tilt seat adjuster stop. For Buick and Cadillac Models, unhook the rear seat trim cover from the rear seat track bar to gain access the rear lead tilt adjuster screw. 7. Locate the rear lead tilt adjuster screw and the old washer stop (1), then install the new stop (2), P/N 25910191 as shown above. For Buick and Cadillac Models, hook the rear seat trim cover to the rear seat track bar. 8. Position the front seat track to the full rear position. 9. Position the front of the seat halfway up to gain access to the front tilt seat adjuster stop. 10. Located the front lead tilt adjuster screw and the old washer stop, then Install a new stop, P/N 25910191 as previously in Step 7. 11. Cycle the seat to the full tilt up and down positions three complete cycles. This cycling will seat the new stops. 12. Verify that the condition has been fixed. 13. Repeat steps 5-12 for the opposite front seat. 14. Disconnect the battery charger from the vehicle. 15. Close the hood. Page 12573 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14027 Use appropriate eye protection. 4. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Important Position the valve body as shown in the following illustrations for positive identification and location of individual parts. Lighting - Brake Lamps Turn Off After Stop/Pedal Applied Brake Light Switch: All Technical Service Bulletins Lighting - Brake Lamps Turn Off After Stop/Pedal Applied TECHNICAL Bulletin No.: 08-08-42-003A Date: August 14, 2009 Subject: Stop Lamps Intermittently Turn Off After Coming to a Complete Stop While Still Having Pressure on Brake Pedal (Replace Stop Lamp Switch) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to provide a new part number. Please discard Corporate Bulletin Number 08-08-42-003 (Section 08 - Body & Accessories). Condition Some customers may comment on the stop lamps turning off prior to the brake pedal reaching the fully released position. Some customers may also comment on the stop lamps turning off while having light pressure on the brake pedal. Some customers with Integrated Trailer Brake Control (ITBC) may comment that the electronic trailer brakes disengage after the vehicle has come to a complete stop. This disengaging of the trailer brakes coincides with the stop lamps turning off. Cause This condition may be caused by not enough pressure being applied to the stop lamp switch to keep the brake lights on. Correction Technicians are to replace the stop lamp switch. The new stop lamp switch has a reduced internal spring apply force, which will allow the lamps to stay on with less applied brake force. 1. Refer to SI for Stop Lamp Switch replacement procedures. 2. Use the new Stop Lamp Switch, P/N 25981009. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 539 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 13242 Fluid Pan: Specifications 6L50/6L80/6L90 - Automatic Transmission Fluid Pan Tighten the bolts in the sequence shown to .................................................................................................................................................. 9 N.m (80 in lb) Page 5763 Engine Control Module: Locations Engine Controls Component Views Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 11312 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 12284 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 6546 Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: All Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 2515 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 11294 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 2667 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 7420 Page 21608 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 9285 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 11395 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure Important: Mark, sort, and organize all the components for assembly. 1. Remove the rocker arm cover. 2. Remove the rocker arms. 3. Remove the rocker arm supports. 4. Remove the pushrods. 5. Clean and inspect the rocker arms and/or pushrods, if necessary. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection. Installation Procedure Important: Be sure to keep parts in order. Parts must be reinstalled into the original location and position. Page 4879 Page 559 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 10245 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 872 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1933 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 4840 Water Pump: Service and Repair Water Pump Replacement (LU3) Tools Required j 41240 Fan Clutch Remover and Installer Removal Procedure 1. Remove the air cleaner outlet duct. 2. Remove the drive belt. 3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 4. Reposition the radiator outlet hose clamps at the surge tank and water pump. 5. Remove the radiator outlet hose from the surge tank. 6. Remove the radiator outlet hose from the water pump. 7. Reposition the water pump inlet hose clamps. 8. Remove the water pump inlet hose. 9. Using J 41240, hold the water pump pulley, remove the water pump pulley bolts. Page 12551 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 8758 Page 12611 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 12287 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 8196 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 11336 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 19747 minutes. After the system restarts, press the "EJECT" soft key to eject and remove the software update disc. Dealers should retain the software update disc for their use. Load the map DVD into the same slot located behind the display screen, DO NOT put in the top slot. Press the "CLOSE" soft key. Press the "OK" soft key. Press the "MENU" hard key. The clock will not be displayed until it is confirmed by completing step 16. Turn the engine OFF, open and close the drivers door. Wait for 10 minutes. Due to the load time of the system, there may be a short delay before the "Map Screen" appears. Restart the engine. After the map screen is displayed, verify that the clock is visible and touch the map screen to confirm that it can be scrolled. If the clock does not appear, repeat programming. The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. Verify that the destination search area is properly displayed. Press the "DESTINATION" hard key. Press "CHANGE SEARCH AREA" soft key. Select the correct area for the vehicle's location. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12186 Page 2913 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 3358 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 16234 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 459 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 7994 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 4445 Notice: Refer to Fastener Notice. 4. Install the rocker arms as follows: 1. Finger start the bolt at location (1) 2. Finger start the bolt at location (2) 3. Finger start the bolt at location (3) 4. Finger start the remaining rocker arm bolts 5. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57-63 degrees clockwise or counterclockwise from the engine front cover alignment tab (2). Important: Once the rocker arms are installed and properly torqued, no additional valve lash adjustment is required. 6. Tighten the rocker arm bolts. Tighten bolts to 30 N.m (22 lb ft). 7. Install the rocker arm cover. Body - Water Leaks Into Rear Footwell Area Rear Door Panel: All Technical Service Bulletins Body - Water Leaks Into Rear Footwell Area Bulletin No.: 07-08-64-004 Date: February 28, 2007 TECHNICAL Subject: Wet or Stained Carpeting in Rear Footwell After Heavy Rainfall or Car Wash (Replace Water Deflector) Models: 2007 Chevrolet Silverado Extended Cab (New Body Style) 2007 GMC Sierra Extended Cab (New Body Style) Condition Some customers may comment on wet or stained carpeting in the rear footwell after a very heavy rainfall or high pressure car wash. Cause This condition may be caused by a void in the loft area around the map pocket on the TIAS water protector (water deflector) inside the door trim. This loft area normally creates an interference condition, causing the adhesive bead to wet out and seal off the water. When a void is present, water intrusion may occur. Correction Carefully remove the interior rear side door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9 or SLT) in SI. Inspect the water deflector for a missing loft. Refer to the illustration above for an example of a correct loft (1) and a missing loft (2). If the loft is missing, replace the water deflector with a new service part. Inspect the opposite side door and replace the opposite side water deflector if necessary. Refer to Rear Side Door Water Deflector Replacement in SI. Parts Information Warranty Information Page 17476 For vehicles repaired under warranty, use the table. Disclaimer Page 23828 Page 24691 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 17871 1. Install the lower ball joint in the knuckle. 2. Install upper ball joint in the knuckle. 3. Install the outer tie rod end in the knuckle. 4. Install the wheel bearing and hub assembly. 5. Install the wheel drive shaft, if equipped. 6. Install the tire and wheel. 7. Remove the support and lower the vehicle. 8. Verify the wheel alignment. Refer to Wheel Alignment Specifications. Page 12748 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 4888 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 3465 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 8601 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Cooling Fan and Shroud Replacement Fan Shroud: Service and Repair Cooling Fan and Shroud Replacement Cooling Fan and Shroud Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill) 2. Remove air inlet duct. 3. Disconnect upper radiator hose from radiator. 4. Disengage the radiator inlet hose clip (2) at the fan shroud. 5. If necessary, reposition the surge tank inlet hose clamp at the radiator. 6. If necessary, remove the surge tank inlet hose from the radiator. Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 13917 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools - J 35910 Drive Axle Seal Clamp Pliers - J 36652-1 Drive Axle Clamp Swage Tool - J 36652-98 Axle Swage Tool Disassemble Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement See: Service and Repair. Important: Use caution when removing the tripot housing (1). 2. Using the appropriate tool, remove the boot clamp (2). 3. Remove the tripot housing (1). Important: If using denatured alcohol or any other recommend cleaning solvent, allow the tripot housing to air dry. 4. Remove any grease from of the housing (1). 5. Using side cutters, remove the small boot retaining clamp (4). 6. Using the appropriate tool, remove the retaining ring (1), then the spider assembly (2), and the boot (3). 7. Using the appropriate tool, remove the any rust in the seal mounting area (grooves) (1). 8. If any of the internal components of the tripot assembly are found to be damaged or have excessive wear, replace the tripot as an assembly. Assemble Procedure Page 2696 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 1081 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 24438 10. Remove the regulator (1) and cables (2) from the vehicle. Installation Procedure 1. Install the regulator (1) and cables (2) to vehicle. Page 8374 module disconnected and the DLC. If the circuit tests normal, replace the last module disconnected. 4. Install a 3-amp fused jumper wire between pin A and pin M of the splice pack. Install another 3-amp fused jumper wire to pin L. 5. Using the open end of the jumper wire at pin L, connect to splice pack terminals B through K and attempt to establish communications with each module connected to the splice pack, one at a time. Each module should be able to communicate. ‹› If communications cannot be established with any module after connecting an individual module, replace the module that caused the no communication. Repair Instructions Perform the Diagnostic Repair Verification after completing the repair. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Control Module References for module replacement, setup, and programming See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * GMLAN Wiring Repairs Page 14678 Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 2 (PCS2) Pressure Switch Manifold (PSM) Page 6775 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 2783 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Page 22862 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 11174 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Locations Steering Angle Sensor: Locations Antilock Brake System Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch Diagrams Memory Positioning Module: Diagrams Power Seat Connector End Views Memory Seat Module X1 (AN3) Memory Seat Module X2 (AN3) Page 18285 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 14220 15. Install the adjusting nut to the hub using the J 2222-C. 16. Adjust the wheel bearings. 17. Install the axle shaft. 18. Install the brake caliper bracket. 19. Install the tire and wheel assembly. 20. Inspect and add axle lubricant to the axle housing, if necessary. 21. Lower the vehicle. Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) Tools Required * J 8614-01 Flange/Pulley Holding Tool * J 22388 Rear Axle Pinion Oil Seal Installer - Rear (8.6 inch, 9.5 inch axle) * J 44414 Rear Axle Pinion Oil Seal Installer (10.5 inch, 11.5 inch axle) Removal Procedure Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies (8.6 inch, 9.5 inch axles). 3. Remove the rear brake calipers (8.6 inch, 9.5 inch axles). 4. Remove the brake rotors (8.6 inch, 9.5 inch axles). 5. Remove the axle shafts (10.5 inch, 11.5 inch axle). 6. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 7. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. Page 17944 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Page 10546 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 8883 Page 6985 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 12003 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the appropriate spark plug wire boot(s) (2) from the spark plug. (left side shown, right similar). 1. Twist the spark plug boot 1/2 turn. 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose in order to remove the spark plug wire boot from the spark plug. 2. Loosen the spark plug 1 or 2 turns. (left side shown, right similar). 3. Brush or air blast away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than 1 plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Page 21843 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 12821 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 8622 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 17394 X800 - X899 Inline Harness Connector End Views X800 Body Harness to Right Rear Door Harness (Crew Cab) Page 8382 Page 23645 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 14781 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 19096 Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab) Page 17007 Fuse: Application and ID Junction Block - Left I/P, Label Electrical Center Identification Views Junction Block - Left I/P, Label Electrical - Various Rear Door Electrical Malfunctions Fuse: All Technical Service Bulletins Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 7083 Vehicle Zoning Strategy Truck Zoning Rear Axle Housing Cover and Gasket Replacement Seals and Gaskets: Service and Repair Rear Axle Housing Cover and Gasket Replacement Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the rear axle. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Remove the rear axle housing cover (2) from the axle housing. 1. Catch the oil in a drain pan. 2. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. Installation Procedure 1. Install the rear axle housing cover (2) and a new gasket. Notice: Refer to Fastener Notice. Important: Do not reuse the rear axle housing cover bolts. 2. Install the new rear axle housing cover bolts (1). Tighten the rear axle housing cover bolts in a crosswise pattern to 40 N.m (30 lb ft). 3. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. 4. Lower the vehicle. Page 15527 Page 1865 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 5955 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 10714 1. Remove the cap from the opening on the fuel tank. 2. Position the fuel tank fill pipe. Notice: Refer to Fastener Notice. 3. Tighten the fuel tank fill pipe clamp (1) at the fuel tank. Tighten the clamp to 2.5 N.m (22 lb in). 4. Connect the fuel fill pipe recirculation line to the fuel tank EVAP line quick connect fitting (2). 5. Install the rear axle vent hose to the clip on the fuel fill pipe bracket. 6. Close the axle vent hose clip. Page 14229 * The pinion oil seal * The differential case bearings 7. Place an alignment mark between the pinion and the pinion yoke. 8. Remove the pinion gear bearing retainer bolts. 9. Remove the pinion gear bearing retainer and the pinion. 10. Remove the selective shim. 11. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. 12. Install the J 8614-01 as shown. 13. Remove the pinion nut while holding the J 8614-01. 14. Remove the washer. 15. Install the J 8614-2 (2) and the J 8614-3 (1) into the J 8614-01 (3) as shown. 16. Remove the pinion yoke by turning the J 8614-3 (1) clockwise while holding the J 8614-01 (3). 17. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. 18. Remove the outer pinion bearing. Page 16041 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 10605 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 9470 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 12214 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 10058 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 20283 Object Sensor - Right Rear Corner Object Sensor - Right Rear Middle Page 16636 Disclaimer Page 11061 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21431 Glove Compartment: Service and Repair Instrument Panel Compartment Door Latch Replacement (with RPO SLT) Instrument Panel Compartment Door Latch Replacement (with RPO SLT) Page 2839 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 9173 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 12958 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 9064 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 2600 Page 47 Disclaimer Locations Knock Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 23553 Page 19266 Hood Sensor/Switch (For Alarm): Diagrams Immobilizer Connector End Views Hood Ajar Switch (AP3/AP8) Page 2388 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 20652 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverage Adjustments are displayed in the Applicable Warranties section. Parts Information Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Replace door handle levers if signs of peeling are present. Note The handle kit contains two door handle levers, replace both sides. Front Side Door Inside Handle Replacement 1. Remove the driver and passenger front side door inside handles. Refer to Front Side Door Inside Handle Replacement in SI. 2. Place front door inside handles on a work bench. Page 8287 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 13545 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 12055 Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 12762 Clutch Control Solenoid Valve: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 3. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) Page 2837 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 15258 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 3436 Window Switch - Left Rear (Crew Cab +A31/Extended Cab +ABV) Page 15243 Brake Pad: Service and Repair Rear Disc Brake Pads Replacement (JH6, JH7) Rear Disc Brake Pads Replacement (JH6, JH7) Page 8627 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 23591 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 11920 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 7382 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 10692 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Regular Cab) Fuel Hose/Pipes Replacement - Chassis (Regular Cab) Removal Procedure Important: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. 3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. Page 6502 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 6395 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 11071 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 8579 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 19474 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 19005 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15842 1 - Rear Seat Audio (RSA) Controller (UK6) 2 - Auxiliary Power Outlet - Console (D07) 3 - Audio Amplifier (UQA) 4 - Auxiliary Power Outlet - Bin (D07) 5 - Noise Compensation Microphone (Y91) 6 - Audio/Video Adapter (U42) Page 1143 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9882 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 8978 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 9716 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 5778 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 21618 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 5993 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 5872 Engine Control Module: Connector Views Engine Control Module Connector End Views Engine Control Module X1 Page 15139 Page 11583 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 3491 3. Determine the caster angle (2). 4. Determine the positive camber (2) or negative camber (3) angle. 5. Remove the pinned adjusting cam insert. Do not reinstall the cam insert. 6. Loosen the upper control arm cam adjustment bolts. Notice: Refer to Fastener Notice. 7. Adjust the caster and the camber angle by turning the cam bolts until the specifications have been met. When the adjustments are complete, hold the cam bolt head in order to ensure the cam bolt position does not change while tightening the nut. Tighten the cam nuts to 190 N.m (140 lb ft). 8. Verify that the caster and the camber are still within specifications. Refer to Wheel Alignment Specifications. When the caster and camber are within specifications, adjust the toe. Front Toe Adjustment Front Toe Adjustment Page 10107 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip (1) from the bracket on the automatic transmission. 9. Unclip the oxygen sensor harness connector from the bracket. 10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 9160 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 6872 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 22650 Power Seat Switch: Diagrams Power Seat Connector End Views Seat Adjuster Switch - Driver (AG1 -AN3) Seat Adjuster Switch - Driver (AN3) Page 2558 Page 4506 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 6949 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 22232 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Page 16495 X601 Inline Harness Connector End Views X601 Right Front Door Harness to Body Harness (ASF) Page 15264 Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor/Drum Refinishing Labor Operations Bulletin No.: 06-05-22-007 Date: November 30, 2006 WARRANTY ADMINISTRATION Subject: Brake Rotor/Drum Refinishing Labor Operations Models: 2005-2007 GM Passenger Cars and Light Duty Trucks (including Saturn) 2005-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X (Canada Only) The purpose of this bulletin is to advise dealership personnel of labor operation changes relating to brake repairs. Existing brake rotor and drum labor operations have been revised to remove the refinishing times and new labor operations have been established for refinishing brake rotors or drums. The changes will become effective with the release of the December 2006 Labor Time Guide. The following changes: Applies to all 2005-2007 vehicles, unless 2005 was the last year of production for that particular model. May apply to 2004 and prior models years if the vehicle was produced after 2005 - e.g. TrailBlazer, Envoy, etc. Where the new labor operations for refinishing rotors or drums do not apply, the existing labor operations will still contain time for refinishing. Always refer to the Labor Time Guide for the appropriate labor operations and time for the vehicle being repaired. Page 5340 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 2525 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 8940 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4516 7. Remove the positive crankcase ventilation (PCV) valve hose from the valve cover and rocker cover. 8. Remove the rocker arm cover bolts. 9. Remove and discard the rocker arm cover bolt grommets, if necessary. 10. Remove the rocker arm cover. 11. Remove and discard the rocker arm cover gasket. 12. Clean and inspect the rocker arm cover, if necessary. Refer to Valve Rocker Arm Cover Cleaning and Inspection. Installation Procedure Important: Do not reuse the rocker cover gasket or the rocker arm cover bolt grommets. Page 20548 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Center Support Bracket Replacement (GMC) Front Bumper Fascia Center Support Bracket Replacement (GMC) Page 12277 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 5038 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 3965 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 8267 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 7670 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 20882 Rear Door Exterior Handle: By Symptom Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Subject: Chrome Outside Door Handle Loose/Cracked at Attachment Screw (Replace Handle) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years, update the Parts Information and add a Caution. Please discard Corporate Bulletin Number 09-08-64-032 (Section 08 - Body and Accessories). Condition Some customers may comment that a chrome outside door handle is loose or cracked in the area of the attachment screws. Cause For 2007 and 2008 models, this condition may be caused by grease used on the attachment screws during the assembly process, which can migrate into the handle screw bosses and cause degradation. Among other contributing factors to this condition is that the initial assembly torque of the attachment screws was too high, which may have helped initiate cracks in the screw bosses. Correction Important When replacing a chrome outside door handle for this condition, be sure to address the following: - Ensure that the attachment screws are free from grease before installing the new handle. Clean the screws with Kent Automotive Acrysol(TM) P/N 20005, or an equivalent grease removing body solvent. - Torque the screws to 6 Nm (53 lb in). Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Page 14610 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Page 10668 4. Inspect for fuel leaks. Page 8010 4. Connect the engine wiring harness electrical connector (4) to the CKP sensor. 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. 7. Perform the crankshaft position system variation learn procedure. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 12687 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 6447 Vehicle Zoning Strategy Truck Zoning Page 1077 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 4401 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3846 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 9229 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 19787 Disclaimer Page 3899 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 7067 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 8757 Auxiliary Body Control Module (XBCM) X2 (Export) Page 22977 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 1976 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14252 Note: Ensure that the outer bearing assembly rotates freely in the hub 9. Using the J 24426 installer (2) and the J 8092 handle (1), turn the rear axle hub over and seat the outer bearing assembly against the retaining ring. 10. Turn the rear axle hub over and install the inner bearing cup. Page 9453 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Interior - Front Seat Cushion Cover Becomes Detached Seat Cushion: All Technical Service Bulletins Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Page 2153 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 16107 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 2510 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23433 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 10862 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 14794 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 2054 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 3726 Power Brake Booster Inlet Hose Replacement Page 8951 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 8084 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 20196 Allison - Automatic Transmission Transmission Mode Switch: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Transmission Internal Mode Switch Page 21033 Rear Door Weatherstrip: Service and Repair Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Rear Side Door Front Auxiliary Weatherstrip Replacement (Extended Cab) Page 1994 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 15738 Negative: Service and Repair Engine Ground Strap Replacement Engine Ground Strap Replacement (4.3L) Removal Procedure 1. Remove the ground strap bolt from the rear of the left cylinder head. 2. Reposition the ground strap from the cylinder head. 3. Remove the ground strap nut from the stud at the front of dash. 4. Remove the ground strap from the stud. Installation Procedure 1. Install the ground strap to the stud. Notice: Refer to Fastener Notice. 2. Install the ground strap nut to the stud at the front of dash. Page 21879 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 12633 from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. * The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. 4. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. Notice: Refer to Fastener Notice. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). Tighten the bolts to 12 N.m (108 lb in). Page 1958 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 23057 Page 8991 Engine Control Module X1 (Pin 25 To 73) Engine Control Module X2 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Page 12135 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 248 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 23096 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 23871 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 11497 11. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid valve. 12. Connect the engine wiring harness electrical connector to the MAP sensor. 13. Connect the chassis fuel feed pipe (1) quick connect fitting to the engine fuel feed pipe. 14. Install the air cleaner outlet resonator. Page 10659 9. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 10. Install the EVAP canister vent solenoid pipe clip (2) to the chassis line. 11. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 12. Install the fuel line clip (1) to the bracket on the automatic transmission. Page 13608 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 6967 Page 6610 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 20530 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Page 5434 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 22973 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 10472 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 15026 21. Remove the spacer plate support bolts (77). 22. Remove the spacer plate support (53). 23. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). Notice: Refer to Fastener Notice. 2. Install the spacer plate support (53) and bolts (77). Tighten the bolts to 10 N.m (89 lb in). Page 3350 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 2092 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 5500 3. Install the water outlet. 4. Install the water outlet tube. Locations High Beam Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 2617 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 4529 Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Tools Required * J 22794 Spark Plug Port Adapter * J 38606 Valve Spring Compressor * J 5892-D Valve Spring Compressor * J 42073 Valve Stem Oil Seal Installer Removal Procedure 1. Remove the required valve rocker arms. 2. Remove the required spark plugs. 3. Install the J 22794 into the spark plug hole. 4. Connect a shop air supply hose and apply compressed air in order to hold the valves in place. 5. Install a flat washer onto the removed rocker arm bolt. 6. Install the bolt and rocker arm for the valve spring requiring removal. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 7. Using J 5892-D compress the valve spring. 1. Hook the slotted end of J 5892-D under the washer on the rocker arm bolt. 2. Apply steady pressure on the valve spring cap until the valve keys are accessible. Page 23829 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Front Center Seat Back Cushion Pivot Cover Replacement (AE7) Seat Back: Service and Repair Front Center Seat Back Cushion Pivot Cover Replacement (AE7) Front Center Seat Back Cushion Pivot Cover Replacement (AE7) Page 11885 Page 10554 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 20639 5. Install the new roll pin that is included in the door handle kit, P/N 88880051. 6. Install the rear side door inside handles. Refer to Rear Side Door Inside Handle Replacement in SI. Customer Information 1. Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition covered under this Special Coverage are to be submitted to the dealer prior to or by July 31, 2011. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Page 20838 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Power) Page 11525 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 2852 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 3477 Alignment: Description and Operation Camber Description Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Page 24669 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 11909 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 4991 Vehicle Zoning Strategy Truck Zoning Page 6281 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 6321 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. 4L60-E/4L65-E/4L70-E - Automatic Transmission Control Module: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (TCM) 1 - Transmission Control Module (TCM) Page 5958 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 21391 Console: Service and Repair Front Floor Console Compartment Bezel Replacement Front Floor Console Compartment Bezel Replacement Page 13719 Disclaimer Page 8338 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 2315 Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 3. Remove the fuel pump/oil pressure sensor fitting, if necessary. Installation Procedure 1. If installing the old fitting, apply sealant to the threads of the fitting. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 2. Install the fitting until snug, if necessary. Notice: Refer to Fastener Notice. 3. Tighten the fuel pump/oil pressure sensor fitting. 1. Tighten the fitting to 15 N.m (11 lb ft). 2. Increase torque until the centerline of the fitting (1) is 50 degrees from the centerline of the crankshaft (2). Page 5006 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 13606 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 14215 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. 8. Remove the adjusting nut. Page 2870 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 13820 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: Customer Interest Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Page 22530 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 7115 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 161 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 1161 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 4867 4. Reposition the surge tank inlet hose clamp at the surge tank. 5. Remove the surge tank inlet hose (1) from the surge tank. Installation Procedure Page 17116 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 8929 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 1919 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 17163 Junction Block - Rear Lamps X2 Page 9862 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 10294 Fuel: Specifications GASOLINE OCTANE Use regular unleaded gasoline with a posted octane rating of 87 or higher. If the octane rating is less than 87, you may notice an audible knocking noise when you drive, commonly referred to as spark knock. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. If you are using gasoline rated at 87 octane or higher and you hear heavy knocking, your engine needs service. GASOLINE SPECIFICATIONS At a minimum, gasoline should meet ASTM specification D 4814 in the United States or CAN/CGSB-3.5 in Canada. Some gasolines may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT). General Motors recommends against the use of gasolines containing MMT. CALIFORNIA FUEL If your vehicle is certified to meet California Emission Standards, it is designed to operate on fuels that meet California specifications. See the underhood emission control label. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp may turn on and your vehicle may fail a smog-check test. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. ADDITIVES To provide cleaner air, all gasolines in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. In most cases, you should not have to add anything to your fuel. However, some gasolines contain only the minimum amount of additive required to meet U.S. Environmental Protection Agency regulations. To help keep fuel injectors and intake valves clean, or if your vehicle experiences problems due to dirty injectors or valves, look for gasoline that is advertised as TOP TIER Detergent Gasoline. Also, your dealer has additives that will help correct and prevent most deposit-related problems. Gasolines containing oxygenates, such as ethers and ethanol, and reformulated gasolines may be available in your area. General Motors recommends that you use these gasolines if they comply with the specifications described earlier. However, E85 (85% ethanol) and other fuels containing more than 10% ethanol must not be used in vehicles that were not designed for those fuels. NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in the fuel system and also damage plastic and rubber parts. That damage would not be covered under your warranty. Some gasolines that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors recommends against the use of such gasolines. Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. If this occurs, return to your dealer for service. NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage would not be covered under your warranty. Some gasolines that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasolines. Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. FUELS IN FOREIGN COUNTRIES If you plan on driving in another country outside the United States or Canada, the proper fuel may be hard to find. Never use leaded gasoline or any other fuel not recommended in the previous text on fuel. Costly repairs caused by use of improper fuel would not be covered by your warranty. To check the fuel availability, ask an auto club, or contact a major oil company that does business in the country where you will be driving. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Locations Coolant Reservoir: Locations Cooling System Component Views Left Front of Engine Compartment (Diesel) 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Page 22758 Vinyl contains unique thermal properties that cause it to expand in cold conditions and retract during hot conditions. Under recommended install temperatures of 21°C (70°F), the tension screws should be adjusted as shown below. Important Be sure to adjust both sides to the same tension. 3. Inspect and verify that the tension screws are adjusted to the 4.76 mm (3/16 in) gap shown in the illustration above. If adjustment is necessary to tighten, turn the screw clockwise with the 1/4 inch key provided. Cause #4 The condition may be caused by over travel of the latch during operation, causing the latch spring to bind. Correction #4 Note A new design of the latch system now contains a latch stop (1) to limit the travel of the latch during operation. This new latch stop prevents over travel and keeps the spring from binding. Verify that the latch system contains a latch stop, noted in the illustration above. If the stop IS NOT present, replace the latch system with latch spring stop service kit, P/N 19213898 and a new latch assembly service kit, P/N 19201885. Warranty Information Locations Ignition Control Module: Locations Engine Controls Component Views Rear of the Engine 1 - Central Sequential Fuel Injection (SFI) Module 2 - Manifold Absolute Pressure (MAP) Sensor 3 G106 4 - Engine Oil Pressure (EOP) Sensor 5 - Ignition Control Module (ICM) 6 - G107 Page 21857 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 17575 Frame Angle Measurement (Express / Savana Only) ........ Page 11205 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 20999 1. Install the striker. 2. Install the spacer, if equipped. 3. Install the upper striker bolt (1). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. 5. Remove the lower bolt. 6. Rotate the striker (2) and the spacer, if equipped, in order to align the lower threaded hole in the striker backing plate. Notice: Refer to Fastener Notice. 7. Tighten the striker bolts. Tighten the door striker bolts to 24 N.m (18 lb ft). Page 16907 Page 11959 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 21403 Page 6199 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 2140 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 10448 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 8694 Disclaimer Page 2419 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 7582 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 13428 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 10968 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 7176 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 8130 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 8415 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 7232 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 2118 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 18869 Disclaimer Page 4037 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 2218 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 9736 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 12736 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 18751 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular Cab +10 Series +ASF) Page 10175 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 8240 Page 24686 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 22509 Locations Horn Relay: Locations Horn Relay The Horn PCB Relay is located in the Fuse Block - Underhood. Note: This relay is a Printed Circuit Board (PCB) Relay, and is not serviceable. Page 12827 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 22546 Seat Heater Switch: Service and Repair Front Seat Heater Switch Replacement (w/o KB6) Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: Customer Interest Park Assist System - Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Page 22395 1 - Heated Seat Switch - Passenger (AN3) 2 - Outside Rearview Mirror (OSRVM) - Passenger 3 Door Trim Seat Heating Elements - Driver (AN3) Page 9490 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 13019 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 17500 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 16560 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 11320 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 2882 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5942 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 9946 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 6716 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 9991 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Service and Repair Acceleration/Deceleration Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Page 12271 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 2427 Page 11947 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 18267 Blower Motor Control Module X2 Electrical - 'No Trailer Connected' Message On DIC Trailer Brake Control Module: All Technical Service Bulletins Electrical - 'No Trailer Connected' Message On DIC TECHNICAL Bulletin No.: 09-05-22-004 Date: November 05, 2009 Subject: No "Trailer Connected" Message on Driver Information Center (DIC) at Startup When Trailer is Connected (Reprogram ITBCM) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Equipped with Integrated Trailer Brake (RPO JL1) Condition Some customers may comment that when they connect their trailer, with the engine off, and after they start the engine, the Trailer Connected message is not displayed on the DIC. With the engine running, if the trailer connector is cycled, the vehicle will detect the trailer and display Trailer Connected. This concern should only affect trailers equipped with trailer brakes on a single axle. Cause The trailer brake control system is only compatible with trailers equipped with electric trailer brakes. The system will not work or detect trailers equipped with any other types of brakes such as surge, air or electric-over-hydraulic trailer brake systems. When a trailer is connected, the Trailer Brake Control Module (TBCM) performs a test to determine if the trailer is equipped with electric trailer brakes. If the trailer wiring or electric trailer brake magnets have additional resistance (caused by poor connections, corrosion, improper splices, etc.), the TBCM may not be able to detect the trailer. Correction A revised calibration has been developed to address these issues. Reprogram the Integrated Trailer Brake Control Module (ITBCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Refer to Trailer Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5160 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 8125 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 2302 4. Position the knock sensor heat shield to the engine block and install the bolt. Tighten the bolt to 10 N.m (89 lb in). 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. Page 12207 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 23864 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Body Rear Inner Panel Carpet Replacement Carpet: Service and Repair Body Rear Inner Panel Carpet Replacement Body Rear Inner Panel Carpet Replacement Page 5271 Page 22419 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 8244 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 16585 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3039 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 15397 Rear Brake Hose Replacement (Caliper - JD9) Rear Brake Hose Replacement (Caliper - JD9) Page 16390 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Seals and Gaskets: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Locations Fuel Pressure Sensor/Switch: Locations Engine Controls Component Views Near the Fuel Tank 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (- Diesel) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Line Pressure Sensor (-LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly - Front (Gas) Page 9069 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 14394 7. Remove the boot from the groove on the transfer case output shaft. 8. Remove the propeller shaft from the transfer case output shaft by sliding the propeller shaft forward. 9. Remove the clamp (1) from the propeller shaft boot (2), if needed. 10. Remove the propeller shaft boot (2) from the propeller shaft, if needed. Installation Procedure 1. Inspect the splines of the transfer case output shaft for a sufficient coating of lubricant. If the output shaft does not have a sufficient coating of lubricant, lubricate the shaft with grease, GM P/N 12345879 (Canadian P/N 10953511), or equivalent lubricant meeting GM Specification 9985830. Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Module Replacement Page 2755 View of the connector when released from the component. View of another type of Micro 64 connector. Page 4606 4. Install the right exhaust manifold. 5. Install the oil level indicator. Page 16892 Page 9934 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 8410 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 7177 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 21191 Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (2WD 2500 HD, 3500) Drivetrain and Front Suspension Frame Front Crossmember Replacement (2WD 2500 HD, 3500) Allison Transmission Fluid Checking Procedure Fluid - A/T: Testing and Inspection Allison Transmission Fluid Checking Procedure Transmission Fluid Check Cold Fluid Check The purpose of the cold check is to determine if the transmission has enough fluid to be operated safely until a hot check can be made. Important: The fluid level rises as fluid temperature increases. DO NOT fill above the COLD CHECK band if the transmission fluid is below normal operating temperatures. 1. Bring the vehicle to a complete stop on a level surface using the service brakes. 2. Ensure that the engine is at low idle RPM (500-800 RPM). 3. With the service brakes applied, put the transmission in the P, PARK, position. 4. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 5. Apply the parking brake and ensure it is properly engaged. 6. Run the engine for at least one minute. Apply the service brakes and shift to D, DRIVE, then to N, NEUTRAL, and then shift to R, REVERSE, in order to fill the hydraulic system. 7. Ensure that the engine is at low idle RPM (500-800 RPM). 8. With the service brakes applied, put the transmission in the P, PARK, position. 9. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 10. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. Important: * If the fluid level is within the COLD CHECK band, the transmission may be operated until the fluid is hot enough to perform a HOT RUN check. If the fluid level is not within the COLD CHECK band, add or drain as necessary to bring it to the middle of the COLD CHECK band. * Always check the fluid level at least twice using the procedure described above. Consistent readings are important in order to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure that it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. Insert the fluid level indicator into the fill tube and remove. Check the fluid level reading. Repeat the check procedure to verify the reading. 11. Perform a hot check at the first opportunity after the normal operating sump temperature of 71-93°C (160-200°F) is reached. Hot Fluid Check Important: The fluid must be hot to ensure an accurate check. The fluid level rises as temperature increases. 1. Operate the transmission in D, DRIVE, range until normal operating temperature is reached. Normal operating temperature is any of the following: * Sump temperature 71-93°C (160-200°F) * Converter-out temperature 82-104°C (180-220°F) * If a transmission temperature gage is not present, check the fluid level when the engine water temperature gage has stabilized and the transmission has been operated under load for at least one hour. 2. Bring the vehicle to a complete stop on a level surface using the service brake. 3. Ensure that the engine is at low idle RPM, 500-800 RPM. 4. With the service brakes applied, place the transmission in the P, PARK, position. 5. Engage the park pawl by slowly releasing the service brakes. The vehicle may move slightly as the pawl engages. 6. Apply the parking brake and ensure it is properly engaged. 7. With the engine running, remove the fluid level indicator from the fill tube and wipe the indicator clean. Important: Always check the fluid level at least twice using the procedure described above. Consistent readings are important to maintaining proper fluid level. If inconsistent readings persist, inspect the transmission vent assembly to be sure it is clean and unclogged. If readings are still inconsistent, contact your nearest Allison distribution or dealer. 8. Insert the fluid level indicator into fill the tube and remove. Check fluid level reading. Repeat the check procedure to verify the reading. Important: Safe operating level is within the HOT RUN band on the fluid level indicator. The width of the HOT RUN band represents approximately 1.0 liter (1.06 quarts) of fluid at normal operating sump temperature. 9. If the fluid level is not within the HOT RUN band, add or drain as necessary to bring the fluid level to within the HOT RUN band. Page 5181 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 5275 Radiator Cooling Fan Control Module: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 3150 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Restraints - Seat Belt Latch Stop Button Availability Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 14843 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 7340 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 10188 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 517 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 20057 Rear Pillar Speaker Replacement Rear Pillar Speaker Replacement Page 6745 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 16307 Fuse Block: Service and Repair Body Wiring Harness Junction Block Replacement Body Wiring Harness Junction Block Replacement Page 3164 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 23877 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 6354 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 11200 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 23393 Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 14563 Fluid Pressure Sensor/Switch: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 12968 View of the connector when released from the component. View of another type of Micro 64 connector. Replacement Wheels Description Wheels: Description and Operation Replacement Wheels Description Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely rusted. * The wheel is severely corroded. Important: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Caution: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Notice: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Page 3170 Knock Sensor: Connector Views Engine Controls Connector End Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Page 487 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 20943 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2463 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 6364 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 13141 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 16075 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 6903 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 7956 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 1838 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 9067 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Page 15472 4. Insert the park brake cable conduit (2) into the equalizer (3). Ensure the locking tabs on the cable conduit are fully engaged into the equalizer. 5. Connect the left rear park brake cable to the intermediate cable connector (1). 6. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling. 7. Adjust the park brake. Refer to Park Brake Adjustment (Disc Brake) Park Brake Adjustment (Drum Brake). Parking Brake Rear Cable Replacement - Right Side (JD9) Parking Brake Rear Cable Replacement - Right Side (JD9) Removal Procedure 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the right park brake cable (1) from the intermediate cable equalizer bar (2). Page 24679 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 21039 Rear Door Window Motor: Service and Repair Rear Sliding Window Module Replacement Rear Sliding Window Module Replacement Removal Procedure Important: The new rear sliding window motor/module is equipped with the bracket and relays. 1. Remove the rear sliding window lower garnish molding. 2. Cycle the rear sliding window to the fully closed position. 3. Remove the screw (1) from the rear sliding window regulator and cables (2). 4. Pull forward on the regulator and cables (2) to release it from the motor/module. 5. Remove the rear sliding window motor/module nuts (2). Page 1200 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 1057 and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 6. Connect a test lamp between the relay coil B+ and the relay coil control circuit. 7. Ignition ON, command the powertrain relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the relay coil control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the relay coil control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 8. Connect a 20A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 9. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 10. If all circuits test normal, test or replace the relay. Component Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Test for 65-110 ohms of resistance between terminals 85 and 86 of the relay. ‹› If the resistance is not within the specified range, replace the relay. 3. Test for infinite resistance between following terminals: * Terminal 30 and 86 * Terminal 30 and 87 * Terminal 30 and 85 * Terminal 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 20A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm of resistance between terminals 30 and 87. ‹› If greater than the specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Relay Replacement (Within an Electrical Center) Relay Replacement (Attached to Wire Harness) * Underhood Electrical Center or Junction Block Replacement * Refer to Programming and Relearning for setup and programming. See: Testing and Inspection/Programming and Relearning 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Pressure Manual Valve Position Switch Logic Transmission Fluid Pressure Manual Valve Position Switch Logic Page 5709 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module 7 - Fuse Block - I/P Page 9272 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 9085 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 10699 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Engine Compartment Fuel Hose/Pipes Replacement - Engine Compartment Removal Procedure Important: Clean all the fuel pipe connections and surrounding areas before disconnecting the pipe in order to avoid possible fuel system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the chassis fuel feed pipe (1) from the engine compartment feed pipe. 4. Remove the fuel pipe retainer nuts (1). 5. Remove the fuel pipe bracket bolt (2). Page 14246 6. Remove the rear wheel bearing adjuster key. 7. Using the J 2222-C wrench, remove the rear wheel bearing adjuster nut. Note: If the oil seal remains on the axle hub, remove the seal using a suitable seal removal tool. Page 13397 - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 3772 7. Cycle the ignition until Drive or Reverse range is attained. Important: Fluid remains in the external circuits and transmission cavities after draining the transmission. 8. Check the transmission fluid level. Page 17018 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Mobile Radio Blunt Cuts 11 - X226 12 - Instrument Panel G108, G110, G111, and G104 Page 7289 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 12529 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 6033 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 23467 For vehicles repaired under warranty, use the table. Disclaimer Page 16436 X325 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) OnStar(R) - Language Change Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Page 15470 intermediate park brake cable connector. 5. Release the left park brake cable from the equalizer (3) by compressing the locking tabs on the cable conduit (2) and pulling the cable rearward. 6. Remove the park brake cable clip bolt. 7. Disconnect the park brake cable eye (1) from the park brake actuator lever (2). 8. Remove the park brake cable (3) from the bracket by pulling the cable conduit rearward to compress the spring and sliding the cable conduit out of the bracket. 9. Remove the park brake cable assembly from the vehicle. Installation Procedure Service and Repair Wiper Gear Box: Service and Repair Air Inlet Grille Panel Replacement Page 11943 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 7047 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 22098 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Page 1011 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 22059 For vehicles repaired under warranty, use the table above. Disclaimer Page 5426 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 5467 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 4996 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Electrical - Electrical Malfunction/Multiple DTCs Technical Service Bulletin # 08-07-30-021E Date: 100607 Electrical - Electrical Malfunction/Multiple DTCs TECHNICAL Bulletin No.: 08-07-30-021E Date: June 07, 2010 Subject: Loss of High Speed GMLAN Communications, Intermittent No Crank, IP Gage Fluctuation, Intermittent Door Lock Cycling, Intermittent Chime Operation, Various IP Warning Lamps Illuminated, Transmission May Not Shift, Communication DTCs U0073, U0100, U0101, U0102, U0109, U0121 or U0140 Set (Repair Backed Out Terminal in Transmission Harness Connector, Repair Open or Shorted GM High Speed LAN Circuits, Open or Shorted Data Link Resistor, Correct Corrosion or Poor Connections in Various Control Module Connectors) Models: 2007-2010 Cadillac Escalade Models, XLR 2009-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Corvette, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Silverado Hybrid, Tahoe Hybrid 2007-2010 GMC Sierra, Yukon Models 2008-2010 GMC Sierra Hybrid, Yukon Hybrid 2008-2009 HUMMER H2 Equipped With 6 Speed 6L80 (RPO MYC) or 6L90 (RPO MYD) or Hybrid Two Mode 2ML70 Automatic Transmission Please Refer to GMVIS Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 08-07-30-021D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: - Instrument panel cluster (IPC) warning lamps may illuminate. - The transmission may not shift or defaults to 2nd gear. - The door locks may cycle by themselves. - The engine may not crank intermittently. - A driver information center (DIC) message is displayed. - The IPC gages may fluctuate. - Applying the brakes may cause the IPC to become erratic and the chimes to operate simultaneously. Depending on the vehicle, technicians may find one or more of the following High Speed GMLAN Communications DTCs set as Current or History: - U0073: Control Module Communications Bus OFF - U0100: Lost Communication With ECM/PCM - U0101: Lost Communication With TCM - U0102: Lost Communication With Transfer Case Control Module - U0109: Lost Communication With Fuel Pump Control Module - U0121: Lost Communication With ABS Control Module - U0140: Lost Communication With Body Control Module (BCM) Cause These conditions may be caused by, but not limited to, any of the following: - The terminal(s) for the High Speed GMLAN Serial Data Bus has backed out of the 16-way electrical connector to the automatic transmission. - The terminal position assurance (TPA) lock in the transmission 16-way electrical connector is not fully seated. - The High Speed GMLAN Serial Data Bus circuits are open or shorted to ground. - Corrosion in various control module connectors. - Intermittent or poor connections in the inline connectors containing the High Speed GMLAN Serial Data Bus circuits. - The data link resistor is open or shorted. - Water intrusion in various control module connectors. A/C - Compressor/Serpentine Belt Noise PROM - Programmable Read Only Memory: All Technical Service Bulletins A/C Compressor/Serpentine Belt Noise TECHNICAL Bulletin No.: 07-01-38-010A Date: October 06, 2009 Subject: Air Conditioning (A/C) Compressor and/or Serpentine Belt Noise at Vehicle Start-up (Reprogram Powertrain Control Module (PCM)) Models: 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon Models Equipped With Air Conditioning (RPOs CJ2 or CJ3) Supercede: This bulletin is being revised to update the Condition and Correction information. Please discard Corporate Bulletin Number 07-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on air conditioning (A/C) compressor slugging and/or serpentine belt or pulley rattle noise at vehicle start-up in warmer outside ambient temperature conditions. Others may describe the noise as a belt chirp or as a thumping/grinding noise coming from the A/C compressor at vehicle start-up. Cause This condition may be caused by the A/C compressor trying to move liquid refrigerant through the system. Correction - A revised PCM calibration has been released to address this condition. Reprogram the PCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. - When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. - When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. - During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information Note *Please use Failure Code 93 for any warranty claims submitted using this bulletin. For vehicles repaired under warranty, use the table above. Page 11024 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 14816 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (367A) and the 1-2 shift solenoid retainer (395). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. 4. Install the pressure control solenoid (377). Notice: Refer to Fastener Notice. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Page 9034 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 219 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 5806 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 22716 Air Dam: Service and Repair Front Air Deflector Replacement (GMC) Front Air Deflector Replacement (GMC) Page 10403 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 16911 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 15696 3. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 5. Install the axle shaft seal using the J 21128. 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. 8. Install the rear axle housing cover. 9. Install the rear wheel speed sensor. 10. Install the tire and wheel assembly. 11. Fill the rear axle. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 12. Lower the vehicle. Page 1080 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 2533 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 16387 Disclaimer Page 23458 Disclaimer Page 8320 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 17661 1. Install the relay rod (5) to the vehicle. 2. Install the pitman arm (2) to the relay rod (5). 3. Install the idler arm (1) to the relay rod (5). Notice: Refer to Fastener Notice. Important: Use a new pitman arm nut. 4. Install the pitman arm nut (4). Tighten the nut to 62 N.m (46 lb ft). Important: Use a new idler arm nut. 5. Install the idler arm nut (6). Tighten the nut to 62 N.m (46 lb ft). 6. Install the steering linkage inner tie rods (3). 7. Install the steering linkage shock absorber to the relay rod, if equipped. 8. Install the engine shield, if equipped. 9. Adjust the front toe. Page 11173 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Page 16877 Fuse Block - I/P, Device Usage 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 3614 Drive Belt: Service and Repair Drive Belt Replacement Removal Procedure 1. Install a 3/8 inch drive breaker bar to the drive belt tensioner arm. 2. Rotate the drive belt tensioner (2) counterclockwise in order to relieve tension on the belt. 3. If equipped without air conditioning (A/C), remove the belt (1) from the pulleys and the drive belt tensioner. 4. If equipped with A/C, remove the belt (1) from the pulleys and the drive belt tensioner. 5. Slowly release the tension on the drive belt tensioner (2). 6. Remove the breaker bar from the drive belt tensioner. 7. Clean and inspect the belt surfaces of all the pulleys. Installation Procedure 1. Route the belt (1) around all the pulleys except the flat idler pulley. 2. Install a 3/8 inch drive breaker bar to the drive belt tensioner arm. 3. Rotate the belt tensioner (2) counterclockwise in order to relieve the tension on the tensioner. 4. If equipped with A/C, install the belt under the flat idler pulley. Page 7784 Vehicle Zoning Strategy Truck Zoning Page 8322 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 13866 Disclaimer Page 2846 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 18719 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra, currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. Your vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Your satisfaction with your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will remove the acoustical padding above the SDM. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. Page 5040 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 7092 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 23331 Disclaimer Electronic Brake Control Module Replacement (JD9, JF3, JF7) Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (JD9, JF3, JF7) Electronic Brake Control Module Replacement (JD9, JF3, JF7) Page 4786 Disclaimer Page 5569 6. Loosely position the Y-pipe support braces w/integral U-bolt clamps (LH and RH) to the underside of the transmission rear mount and the crossover pipe as shown. The top ends of the braces attach to the underside of the transmission rear mount. The bottom ends of the braces attach to the crossover pipe using the integral U-bolt clamps. The braces support the LH leg of the Y-pipe where it crosses over the vehicle to meet the Y-pipe collector. 7. Install the two nuts to the transmission rear mount and the two nuts to the U-bolt clamps. Tighten - Tighten the new transmission mount nuts to 25 Nm (18 lb ft). - Tighten the two U-bolt clamps to 30 Nm (22 lb ft). 8. Lower the vehicle. 9. Verify that the condition has been fixed. Parts Information -- Kit P/N 15076982 includes a flex coupler, two support brace rods w/integral U-bolt pipe clamps, two U-bolt pipe clamps (for use with flex coupler) and two new transmission mount studs w/fasteners. - Kit P/N 15076990 includes a flex coupler and two U-bolt pipe clamps. Warranty Information For vehicles repaired under warranty, use: For locally obtained flex coupling, submit the amount into the NET amount field. Disclaimer Page 10572 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Important: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 14600 Transmission Mode Switch: Locations Shift Lock Control Component Views Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 3316 Notice: Refer to Fastener Notice. Important: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3). Tighten the TORX screw to 1.3 N.m (11.5 lb in). Important: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 1. Apply tire soap to the rubber portion of the valve stem (1). 2. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 24754 Wiper Motor: Connector Views Wiper/Washer Connector End Views Windshield Wiper Motor Page 15291 Heater Core Cover Replacement Heater Core: Service and Repair Heater Core Cover Replacement Heater Core Cover Replacement Page 8395 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 23094 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 2721 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 3208 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Page 6823 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Notice: Refer to Fastener Notice. 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 N.m (92 lb in). 5. Install the control valve assembly. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 17126 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 10237 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 3306 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 15783 Alternator: Diagrams Generator X1 (Gas) Generator X1 (Gas) Locations Ignition Control Module: Locations Engine Controls Component Views Rear of the Engine 1 - Central Sequential Fuel Injection (SFI) Module 2 - Manifold Absolute Pressure (MAP) Sensor 3 G106 4 - Engine Oil Pressure (EOP) Sensor 5 - Ignition Control Module (ICM) 6 - G107 Page 22594 Passenger Door Switch (PDS) X3 (AN3/DL3) Page 18480 Heater Core: Service and Repair Heater Core Replacement Heater Core Replacement Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 13817 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 13453 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 19712 Page 2138 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Allison - Automatic Transmission Pressure Regulating Solenoid: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Mod Main Pressure Control Solenoid Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Page 10469 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 23557 Page 4963 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 5179 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 22390 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 11800 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. Remove the tire from the wheel. Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 3. Remove the tire pressure sensor nut. 4. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Page 15856 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 23438 Notice: Refer to Fastener Notice. 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 N.m (62 lb in). Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. Install the tire on the wheel. Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 17162 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 495 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 12547 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 318 For vehicles repaired under warranty, use the table. Disclaimer Page 8366 Information Bus: Description and Operation Data Link Communications Description and Operation Circuit Description The communication among control modules is performed through the high speed GMLAN serial data circuits and the low speed GMLAN serial data circuit. The modules that need real time communication are attached to the High Speed GMLAN network. The body control module (BCM) is the gateway between the high and low speed networks. Refer to Body Control System Description and Operation for more information about the gateway. Signal supervision is the process of determining whether an expected signal is being received or not. Some messages are sent on a periodic basis and are interpreted as a heartbeat of a device. If such a signal is lost, the signal supervision part of the software will set a no communication DTC (U. code) against the missing device. This code is mapped on the Tech 2 screen as a code against the physical device. A lost communication DTC typically is set in modules other than the module with a communication failure. GMLAN High Speed Circuit Description The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit. The serial data is transmitted on 2 twisted wires that allow speed up to 500 Kb/s. The twisted pair is terminated with two 120-ohm resistors, one is internal to the engine control module (ECM) and the other is after the electronic brake control module (EBCM), or if equipped, the suspension control module. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds 1 volt to the high speed GMLAN serial data bus (+) and subtracts 1 volt from the high speed GMLAN serial data bus (-) wire. If a communication signal is lost, the application will set a no communication code against the respective control module. This code is mapped on the Tech 2 screen as a code against the physical device. Note: a loss of serial data DTC does not represent a failure of the module that the code is set in. The high speed GMLAN serial data allows communication between the body control module (BCM), ECM, transmission control module (TCM), vehicle communication interface module (VCIM), 4WD control module, EBCM, and the suspension control module depending on RPO. GMLAN Low Speed Circuit Description The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial data circuit. The serial data is transmitted over a single wire to the appropriate control modules. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pulse train sent out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this creates a logic state of 0 on the buss. When the buss is pulled low, 0 volts, it is translated as a logic state of 1. To wake the control modules connected to the GMLAN low speed serial data buss, a wake up signal is sent out over the buss. Modules connected to the GMLAN low speed buss can be part of a virtual network as described in GMLAN High Speed Circuit Description above. The modules on the GMLAN low speed serial data buss are connected to the buss using several splice or "star" connectors separating groups of modules. The following lists state the splices and modules connected to the low speed serial data circuits: I/P Splice * Data link connector (DLC), connected only to the instrument panel (I/P) splice * Amplifier (Amp) * Rear seat audio (RSA) * Vehicle communication interface module (VCIM) * Digital radio receiver (DRR) * Inside rearview mirror module (ISRVM), connected through the mid I/P fuse block * Instrument panel cluster (IPC) * Body control module (BCM) * Theft deterrent module (TDM) * Heater ventilation and air conditioning (HVAC) * Radio * Driver door switch (DDS), connected through the left I/P fuse block * Passenger door switch (PDS), connected through the right I/P fuse block Body Splice * Articulating running board module (ARBM) * Ultrasonic park assist (UPA) * Memory seat module (MSM) * Liftgate module (LGM) * Passenger presence system (PPS) * Inflatable restraint vehicle rollover sensor (ROS) * Inflatable restraint sensing and diagnostic module (SDM) Data Link Connector (DLC) Cooling System, A/C - Aluminum Heater Cores/Radiators Radiator: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 6211 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 16671 Disclaimer Front Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Front Seat Adjuster Switch Knob Replacement Front Seat Adjuster Switch Knob Replacement Page 8486 Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 10540 Page 24155 Page 2874 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 11700 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 6833 Vehicle Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor (VSS) Page 2807 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 11290 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 7475 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections Page 11664 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 11817 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 9084 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 14093 Procedures to Diagnose/Chafed Wiring Harness at Trans Case Information for the Procedures to Diagnose and Repair the Above Conditions 1. Perform the Diagnostic System Check-Vehicle to begin your diagnosis of these conditions. 2. Perform a thorough visual inspection of the vehicle. 3. Depending on the vehicle, some of the procedures may not be applicable. 4. The following procedure is the only one applicable to the Corvette and XLR. Chafed Wiring Harness at Transmission Case Retaining Clip and Inspection of the 16-way Electrical Connector for Backed Out Terminals 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Locate the 16-way electrical connector on the right side of the automatic transmission as shown. 5. Inspect for a pinched/cut wiring harness where it is attached at the transmission by a metal attachment clip as shown. Inspect any of these harness clips that you may observe as needed. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. Page 4363 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Guidelines Caution: To avoid personal injury when exposed to plastic media blast, hand and/or lathe sanding dust, primer, color coat, and clearcoat, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs and protective gloves and clothing. Evaluating Damage Important: * Inspect the wheel for corrosion, scrapes, gouges, etc. Damage MUST NOT be deeper than what can be sanded or polished off. * Inspect the wheel for cracks. If cracks are found, discard the wheel. * ALL wheels with bent rim flanges must not be repaired or refinished. * The re-machining and the re-clear coating of aluminum wheels is not recommended in the dealer environment due to concerns of repair durability. * Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Aluminum Wheel Refinishing General Recommendations/Options * Painted aluminum wheels use a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. (See option number 1). * If the clearcoat is damaged, it is possible to refinish with clearcoat only, however, the required refinishing process cannot be performed in the dealer environment. Refer to Refinishers Responsibility (Repair option number 2). * Re-plating of chrome-plated aluminum wheels is not recommended. Repair Option Number 1 Material Required/Information Resources * The Paint Manufacturer's Color Book * Refer to the latest GM Approved Refinish Materials Booklet (GM 4901 MD-2005) for specific products for aluminum refinishing. * To access the booklet, go to www.gmgoodwrench.com. Click on GM Collision Parts. Click on GM Technical Repair Information, select Paint Shop. * A Color Compatibility chart is also at this site defining what colors are used on what models. Important: Chemical strippers are not recommended. * Refer to specific Paint Manufacturers for refinish procedures and process pertaining to "Aluminum Refinishing". The procedure requires the wheel surface to be plastic media blasted to remove old paint or clearcoat. General Color Selection * If the wheels being painted were previously clearcoated aluminum, and a painted aluminum look is desired, using Corsican Silver WAEQ9283 for a fine "aluminum-like" look, or Sparkle Silver WA9967 for a very bright look. Body color is another option to the customer that may also be used. * Some specific colors may be recommended on certain models. * If painting wheels that were previously clearcoated aluminum, it is recommended that all 4 wheels and their center caps be refinished to maintain color uniformity. General Refinishing Procedures - Removal 1. Remove the wheels from the vehicle. The tires may remain mounted on the wheels. 2. Remove the balance weights and mark their locations on the tire. 3. Remove excess grease, etc. from the wheels with wax and grease remover. 4. Have the wheels plastic media blasted to remove the clearcoat. Important: MASK OFF ALL MOUNTING SURFACES, whenever a wheel is refinished. The mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. Page 6325 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 14626 Transmission Speed Sensor: Locations Power Take-Off Power Take-Off (PTO) Component Views Front Frame Rail 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor 4 - Automatic Transmission Input Shaft Speed (AT ISS) Sensor 5 - Automatic Transmission 6 - Vehicle Speed Sensor (VSS) 7 - X124 8 - Power Take Off (PTO) Module 9 - X175 Page 12868 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 1767 * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Page 10656 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip (1) from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 4886 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 15882 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 6662 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 14624 Transmission Speed Sensor: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 22843 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Page 20042 Speaker - Right Front Tweeter Page 7755 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 7001 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 8336 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 4111 Page 7401 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 12140 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 8996 5. Disengage the retainer tabs securing the ECM to the bracket. 6. Remove the ECM. Installation Procedure 1. Install the bottom ECM tabs into the bracket. 2. Push the ECM in securing the ECM to the bracket. Page 18154 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Page 13595 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 2221 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 10306 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 12106 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10970 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 7003 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Battery Negative Cable Replacement Negative: Service and Repair Battery Negative Cable Replacement Battery Negative Cable Replacement (4.3L) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the air cleaner outlet resonator. 3. Disconnect the engine wiring harness electrical connector (1) from the battery current sensor. 4. Remove the battery current sensor (3) clip from the battery tray. Page 21790 Page 11793 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 7965 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 20818 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16915 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Torque Converter: Customer Interest A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 19016 Seat Belt Buckle: Service and Repair Rear Seat Center Belt Buckle Replacement (Ext Cab w/AM7) Rear Seat Center Belt Buckle Replacement (Ext Cab w/AM7) Page 3111 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 10903 Page 21602 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 14786 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 21132 Endgate Emblem/Nameplate Replacement (Chevrolet FFU) Endgate Emblem/Nameplate Replacement (Chevrolet FFU) Page 5357 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 520 Page 23869 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 4829 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: * Spark plug fouling-Colder plug * Pre-ignition causing spark plug and/or engine damage-Hotter plug 3. Inspect the terminal post (1) for damage. * Inspect for a bent or broken terminal post (1). * Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. 4. Inspect the insulator (2) for flashover, carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: * Inspect the spark plug boot for damage. * Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. 5. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Page 10006 4. Connect the engine wiring harness electrical connector (1) to the EVAP purge valve solenoid. 5. Position the EVAP canister purge solenoid tube, and connect the tube quick connect fitting (1) to the EVAP purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service. 6. Install the air cleaner outlet resonator. Page 18711 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 23872 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 19572 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5793 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 16427 Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Crew Cab) Rear Side Door Window Regulator Motor Replacement (Crew Cab) Page 21501 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Crew Cab) Body Lock Pillar Trim Replacement (Crew Cab) Page 4842 Important: After assembly, the hose clamp tangs (water pump end) must point forward and the upper tang should be level with the outside diameter of the water pump inlet hose. 5. Install the water pump inlet hose. 6. Position the water pump inlet hose clamps. 7. Install the radiator outlet hose to the water pump. 8. Install the radiator outlet hose to the surge tank. 9. Position the radiator outlet hose clamps at the surge tank and water pump. 10. Install the drive belt. 11. Install the air cleaner outlet duct. 12. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 13. Inspect the cooling system for leaks. Page 5041 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 18779 Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Crew Cab +ASF) Page 8635 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice Silicon Contamination of Heated Oxygen Sensors Notice Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Page 12238 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 11370 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Locations Accelerator Pedal Position Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Allison - Automatic Transmission Transmission Mode Switch: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Transmission Internal Mode Switch Page 5584 3. If vehicle has a extended cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the underbody studs. 4. Install the exhaust heat shield nuts. Tighten the nuts to 9 N.m (80 lb in). 5. If vehicle has a regular cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the studs. 6. Install the exhaust heat shield nuts. Tighten the nuts to 9 N.m (80 lb in). 7. Install the catalytic converter. Page 6738 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Displays and Gages Connector End Views Driver/Vehicle Information Display: Diagrams Displays and Gages Connector End Views Displays and Gages Connector End Views Driver Information Center (DIC) Switch Page 1157 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 17637 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Page 4698 12. Remove the positive crankcase ventilation (PCV) valve hose from the valve and rocker cover. 13. Disconnect the power brake booster vacuum hose from the vacuum fitting. 14. Remove the intake manifold - upper studs. 15. Remove the front 2 throttle body studs. 16. Remove the intake manifold - upper. 17. Remove and discard the intake manifold - upper gasket. 18. Remove and discard the O-ring seal from the fuel meter body. Page 3366 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 15084 Transmission Position Switch/Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 9780 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 18353 Control Assembly: Diagrams HVAC - Manual HVAC Connector End Views HVAC Control Module X2 HVAC Control Module X3 Page 11856 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 6303 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 9296 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Audio System - Static/Ignition Noise on AM Band Ignition Cable: All Technical Service Bulletins Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Page 10420 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 7905 Page 21168 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 10576 View of the connector when released from the component. View of another type of Micro 64 connector. Page 13490 Transmission Speed Sensor: Locations Power Take-Off Power Take-Off (PTO) Component Views Front Frame Rail 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor 4 - Automatic Transmission Input Shaft Speed (AT ISS) Sensor 5 - Automatic Transmission 6 - Vehicle Speed Sensor (VSS) 7 - X124 8 - Power Take Off (PTO) Module 9 - X175 Page 12194 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 11981 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 2417 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 6474 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 12311 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 1829 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 16048 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 270 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 14706 Page 2358 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 13169 Automatic Transmission Dipstick - Dipstick Tube: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Filler Tube and Seal Replacement Removal Procedure 1. Unlock the transmission oil level indicator. 2. Remove the transmission oil level indicator. 3. Remove the transmission. 4. Remove the oil level indicator tube (1). 5. Remove the seal (2) from the transmission. Installation Procedure Page 9533 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 11257 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 16066 View of the connector when released from the component. View of another type of Micro 64 connector. Page 9846 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 10004 Canister Purge Solenoid: Service and Repair Evaporative Emission Canister Purge Solenoid Valve Replacement Removal Procedure 1. Remove the air cleaner outlet resonator. 2. Disconnect the evaporative emission (EVAP) canister purge solenoid valve tube quick connect fitting (1) from the EVAP purge solenoid valve. 3. Reposition the tube out of the way. 4. Disconnect the engine wiring harness electrical connector (1) from the EVAP purge valve solenoid. Page 15217 Rear Brake Caliper Bracket Replacement (JD9) Rear Brake Caliper Bracket Replacement (JD9) Page 15808 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 10683 21. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 N.m (18 lb ft). 22. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. 23. Lower the vehicle. 24. Remove the caps from the fuel rail and EVAP line. 25. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. 26. Connect the fuel feed line (1) quick connect fitting to the fuel rail. 27. Install the fuel fill cap. 28. Connect the negative battery cable. 29. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Locations Daytime Running Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 6210 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 20048 Speaker: Service and Repair Radio Front Floor Console Speaker Replacement Radio Front Floor Console Speaker Replacement Page 3873 Page 23415 Frequently Asked Questions Disclaimer Page 10730 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 16937 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 18336 Disclaimer Page 7002 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 8398 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required j 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the oil pressure sensor. Do not allow debris to enter the engine. 1. Disconnect the fuel pump/oil pressure sensor electrical connector (3). 2. Using J 41712, remove the fuel pump/oil pressure sensor. Air Bag System - DTC B0071/B0074/B0081 Code Clearing Seat Occupant Sensor: All Technical Service Bulletins Air Bag System - DTC B0071/B0074/B0081 Code Clearing Bulletin No.: 07-09-41-004 Date: June 13, 2007 INFORMATION Subject: New Procedure for Clearing Passenger Presence System (PPS) and Sensing and Diagnostic Module (SDM) DTCs B0071, B0074, B0081 Models: 2006-2008 Buick Lucerne 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Monte Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Silverado, Suburban, Tahoe 2007-2008 GMC Yukon, Yukon Denali, Yukon XL, Yukon XL Denali A condition exists where the passenger presence system (PPS) may continue to output a fault to the sensing and diagnostic module (SDM) after the PPS has been cleared. The fault may continue to report to the SDM if the buss has not been allowed to go to sleep prior to clearing B0081 DTC in the SDM. If B0071, B0074 or B0081/0F is received, the following procedure should be followed to clear the codes. With the Ignition OFF, open and close the driver door. With a scan tool, clear PPS DTC (B0071 or B0074). While continuing to keep the doors closed, wait 60 seconds with the ignition OFF. DO NOT operate any functions in the vehicle during this time. Verify that the PPS does not have any DTCs. If PPS DTCs exist, please perform the necessary repair. With the scan tool, clear DTC B0081. Disclaimer Page 14234 25. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 26. Install the propeller shaft yoke retaining clamps and the bolts. Tighten the propeller shaft yoke retaining clamp bolts to 25 N.m (18 lb ft). 27. Install the axle shafts. 28. Fill the axle with axle lubricant. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 29. Lower the vehicle. Page 12989 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 16772 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 9682 7. Remove the HO2S pigtail electrical connector clip (9) from the fuel line bracket. 8. Remove the HO2S (1). Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (1). Shift Lever Replacement Shifter A/T: Service and Repair Shift Lever Replacement Shift Lever Replacement Removal Procedure 1. Remove the steering column shroud. 2. Roll back the shift lever seal on the shift lever until the shift lever bolt is exposed. 3. Disconnect any electrical connectors as needed. 4. Remove the shift lever bolt (2). 5. Remove the shift lever (1). Installation Procedure Procedures Fuel Injector: Procedures Fuel Injector Cleaning Tools Required * J 38500-A Fuel Injector Cleaner * J 39021 Fuel Injector Coil and Balance Tester * J 39021-210 Injector Tester Adapter Box * J 39021-301 V6 Fuel Injector Test Adapter * J 41413 EVAP Pressure and Purge Station * J 44466-10 Regulator and Hose Assembly * J 44466-11 IAFM Fuel Transfer Tube Recycling Block * J 44466-12 CSFI Fuel Metering Body Jumper Block * J 44466-13 Screws 1. Loosen the fuel fill cap to relieve vapor pressure in the fuel tank. 2. Relieve the fuel system pressure. 3. Remove the positive crankcase ventilation (PCV) clean air tube from air inlet duct and set aside. 4. Remove the resonator and air inlet duct from throttle body. 5. Remove the brake booster vacuum hose and connector from intake manifold. 6. Remove the electrical connector from the central sequential fuel injection (CSFI) fuel metering body. 7. Remove the spark plug wires from 1, 3 and 5 from the distributor cap. 8. Remove the fuel feed pipe bracket stud (3). 9. Remove the fuel pipe retainer nuts (2) and retainer (1). 10. Remove fuel feed pipe (4). Important: Make sure that the fuel pipe O-rings, washers, and spacers are present and in their proper position. Page 13206 Notice: Refer to Fastener Notice. 5. Install the oil pan bolts. Tighten the bolts alternately and evenly to 11 N.m (97 lb in). 6. Install the catalytic converter. 7. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to 25 N.m (18 lb ft). 8. Apply a small amount of sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the threads of the oil pan drain plug, if equipped. 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. Page 10195 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 15175 Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement (JH6, JH7) Front Wheel Speed Sensor Replacement (JH6, JH7) Page 6946 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 12583 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission: * The torque converter clutch solenoid (1) * The pressure control solenoid (2) * The internal wiring harness (3) * The 2-3 shift solenoid (4) * The 1-2 shift solenoid (5) * The transmission fluid pressure manual valve position switch (6) * The 3-2 shift solenoid (7) * The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wiring harness electrical connectors from the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) Page 21394 Front Floor Console Compartment Bezel Replacement Front Floor Console Compartment Bezel Replacement Page 11523 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Locations Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 12278 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 22131 Memory Seat Module X6 (AN3) Page 4948 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 6206 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 20241 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 12273 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 20351 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 20457 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11703 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 4959 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 22473 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 9260 Page 7102 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 24688 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 2934 Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CMP sensor, install a NEW O-ring seal onto the sensor. 2. Install the CMP sensor to the wiring harness jumper. 3. Connect the CMP sensor wiring harness jumper to the CMP sensor. 4. Lubricate the O-ring seal with clean engine oil. 5. Install the CMP sensor and wiring harness jumper to the engine front cover. Notice: Refer to Fastener Notice. 6. Install the CMP sensor bolt. Tighten the bolt to 10 N.m (89 lb in). 7. Install the water pump. 8. Connect the engine wiring harness electrical connector (7) to the CMP sensor wiring harness jumper. Page 8106 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 12013 Clutch Control Solenoid Valve: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 9149 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 5336 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Page 8385 Page 14104 5. Inspect the wiring harness near the data link resistor, between the truck box and frame for chafed/shorted wiring as shown. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > Data Link Resistor in SI. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Disconnect the electrical connector from the data link resistor. 7. Test the resistor for 110-130ohm. ‹› If not within the specified range, replace the data link resistor. ‹› If within the specified range, refer to Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. 8. Connect the electrical connector to the data link resistor. Secure the resistor as needed. 9. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 10. Lower the vehicle. 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 12. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Inspection of Engine Harness Connector X109 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X109 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X109 in SI. 4. Before disconnecting, verify the connector is fully seated together even though the lever is locked down as shown. If the connector is not fully seated, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Connector Repairs in SI. 5. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Engine Harness Connector X115 for Backed Out or Bent Terminals and Poor Connections 1. Turn OFF the ignition and all accessories. Page 17288 X110 Inline Harness Connector End Views X110 Engine Harness (-Diesel) or Engine Chassis Harness (Diesel) to Front Axle Harness (NQF/NQG/NQH/NP2) Page 22625 Power Seat Motor Position Sensor: Diagrams Power Seat Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Page 5312 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 3926 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 5953 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 23588 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 21644 Outside Rearview Mirror References Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... ............................................. 16.5 quarts (15.6 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 6127 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 9657 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 15403 Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) Page 8205 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Allison - Automatic Transmission Control Module: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Page 12032 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (367A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Page 5110 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 2253 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 10756 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Service and Repair Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement The Traction Control Switch is part of the Accessory Switch Assembly. To replace the Traction Control Switch please refer to Accessory Switch Replacement (without RPO SLT) Accessory Switch Replacement (with RPO SLT). Page 11046 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 1599 4. If installing the old sensor, apply sealant to the threads of the sensor. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 5. Using J 41712, install the sensor. Tighten the sensor to 30 N.m (22 lb ft). 6. Connect the fuel pump/oil pressure sensor electrical connector (3). 7. Check and adjust the engine oil level, if necessary. Page 12051 Shift Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 18963 Disclaimer Page 2072 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11617 Knock Sensor: Connector Views Engine Controls Connector End Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Page 6542 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 16695 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 13227 11. Ensure that no gap is present between the cap and the fitting. 12. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 13. A hidden yellow identification band indicates proper joint seating. 14. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check. Page 4741 2. Remove the J 38834. 3. Install the balance shaft. Page 9977 13. For vehicles equipped with 4WD perform the following steps, connect the engine wiring harness electrical connector (7) to the left front HO2S electrical connector (8). 14. Install the left front CPA retainer. 15. Connect the engine wiring harness electrical connector (1) to the left rear HO2S electrical connector (2). 16. Install the left rear HO2S electrical connector clip to the frame. 17. Install the CPA retainer. Page 16159 Vehicle Zoning Strategy Truck Zoning Page 10163 Disclaimer Page 10858 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 4947 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 142 Parking Assist Control Module: Diagrams Object Detection Connector End Views Rear Object Sensor Control Module X1 Rear Object Sensor Control Module X2 Page 8402 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 9097 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 7316 Page 11779 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 12871 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 4195 Tire Pressure Module: Service and Repair Control Module Setup Remote Control Door Lock Receiver (RCDLR) Setup After remote control door lock receiver assembly replacement, the following procedures must be performed in the order that they appear for the tire pressure monitor (TPM) System to function properly. The RCDLR also requires keyless entry transmitter programming after replacement. Refer to Transmitter Programming. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool select Vehicle Control System. 4. Select Module Setups. 5. Select Remote Control Door Lock Receiver. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle drivers door placard sticker. 9. Select the rear tire pressure as noted on the vehicle drivers door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After RCDLR assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the RCDLR memory. Refer to Tire Pressure Sensor Learn. Page 13408 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-023 Date: 080508 A/T - Fluid Leak From Bell Housing Area TECHNICAL Bulletin No.: 08-07-30-023 Date: May 08, 2008 Subject: 4L60-E/4L65-E/4L70‐E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Replace Torque Converter Hub-to-Oil Pump Seal Assembly) Models: 2007-2008 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe, TrailBlazer 2007-2008 GMC Envoy, Savana, Sierra, Yukon, Yukon XL 2007-2008 HUMMER H2 2007-2008 Saab 9-7X with 4L60-E, 4L65-E or 4L70‐E Automatic Transmission (RPOs M30, M32 or M70) and 4.8L, 5.3L or 6.0L V8 Engine Attention: This bulletin applies to vehicles built prior to December 2007. Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. Cause Investigation of 2007 transmissions has shown wear of the torque converter hub-to-pump seal (243, illustrated in the Oil Pump Disassembled View in SI). Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If the leak is coming from the bell housing replace the torque converter seal. Parts Information Warranty Information (excluding Saab U.S. Models) Page 2414 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 6179 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors HVAC - Automatic Control Module HVAC: Locations HVAC - Automatic HVAC Component Views HVAC Module 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P C4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Lighting - Turn Signals Have Increased Flash Rate Body Control Module: All Technical Service Bulletins Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 18421 Disclaimer Page 6236 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 16957 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 11177 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 12719 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 7229 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 13632 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (367A) and the 1-2 shift solenoid retainer (395). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. 4. Install the pressure control solenoid (377). Notice: Refer to Fastener Notice. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Page 16123 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Service and Repair Keyless Entry Transmitter Battery: Service and Repair Transmitter Battery Replacement Removal Procedure 1. Insert a small bladed tool, at the slot provided near the key ring hole (5), between the two halves (6, 4) of the transmitter case. 2. Twist the small bladed tool, between the two halves in order to separate the case. 3. Remove the battery (2) from the transmitter. Installation Procedure 1. Install the battery (2) with the positive side down into the transmitter. 2. Ensure the seal (7) is in position. Align the two halves of the case (6, 4), and snap the two halves together. 3. Verify the operation of the transmitter. Page 5345 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 9213 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 14804 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 16604 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 11566 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 15180 3. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 4. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 5. Install the axle shaft seal using the J 21128. 6. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 7. Install the axle shaft. 8. Install the rear axle housing cover. 9. Install the rear wheel speed sensor. 10. Install the tire and wheel assembly. 11. Fill the rear axle. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 12. Lower the vehicle. Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure Important: Mark, sort, and organize all the components for assembly. 1. Remove the rocker arm cover. 2. Remove the rocker arms. 3. Remove the rocker arm supports. 4. Remove the pushrods. 5. Clean and inspect the rocker arms and/or pushrods, if necessary. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection. Installation Procedure Important: Be sure to keep parts in order. Parts must be reinstalled into the original location and position. Page 2863 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. OnStar(R) - Availability for Hearing Impaired Communications Control Module: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 22024 Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement (Extended Cab) Sunroof Window Replacement (Extended Cab) Removal Procedure 1. Position the sunshade panel fully rearward. 2. Position the sunroof window panel to the vent position. 3. Remove the sunroof window panel screws from the sunroof window panel. 4. Remove the sunroof window panel from the sunroof module. Installation Procedure 1. Position the sunroof window panel to the sunroof module. Ensure that the information logo stencil is towards the rear of the sunroof opening. Notice: Refer to Fastener Notice. 2. Install the sunroof window panel screws to the sunroof window panel. Tighten the sunroof window panel screws to 4 N.m (35 lb in). 3. Adjust the sunroof window panel as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment. 4. Inspect the sunroof window panel for proper operation. Page 6212 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 19651 minutes. After the system restarts, press the "EJECT" soft key to eject and remove the software update disc. Dealers should retain the software update disc for their use. Load the map DVD into the same slot located behind the display screen, DO NOT put in the top slot. Press the "CLOSE" soft key. Press the "OK" soft key. Press the "MENU" hard key. The clock will not be displayed until it is confirmed by completing step 16. Turn the engine OFF, open and close the drivers door. Wait for 10 minutes. Due to the load time of the system, there may be a short delay before the "Map Screen" appears. Restart the engine. After the map screen is displayed, verify that the clock is visible and touch the map screen to confirm that it can be scrolled. If the clock does not appear, repeat programming. The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. Verify that the destination search area is properly displayed. Press the "DESTINATION" hard key. Press "CHANGE SEARCH AREA" soft key. Select the correct area for the vehicle's location. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt ..................................................................................................................... .......................................................... 95 N.m 70 lb ft Crankshaft Pulley Bolt ...................................... ............................................................................................................................................. 58 N.m 43 lb ft Drivetrain - Rear Drive Axle Whine Noise Slip Yoke: Customer Interest Drivetrain - Rear Drive Axle Whine Noise Bulletin No.: 06-04-17-002A Date: January 12, 2007 TECHNICAL Subject: Rear Drive Axle Whine Noise (Replace Slip Yoke Assembly) Models: 2004-2007 Chevrolet Silverado (Classic) 1500 Series 2WD Crew Cab Models (C15543) 2004-2007 GMC Sierra (Classic) 1500 Series 2WD Crew Cab Models (C15543) Supercede: This bulletin is being revised to include additional model information. Please discard Corporate Bulletin Number 06-04-17-002 (Section 04 - Driveline/Axle). Condition Some customers may comment on a slight axle whine noise heard only at certain speeds, typically on coast conditions between 72-96 km/h (45-60 mph). Cause "Inherent" ring and pinion gear whine. All gear driven units, such as automotive rear axles, produce some level of noise that cannot be eliminated with conventional adjustments and repairs. "Inherent" axle noise can be described as a slight noise heard only at a certain speed (typically between 72-96 km/h (45-60 mph) on most General Motors(R) trucks). The presence of this noise is not indicative of a functional concern with the axle assembly. However, some customers may find that this inherent axle noise is unacceptable. Correction Using the service procedures in SI, replace the propshaft front slip yoke and u-joint with a tuned damper slip yoke with u-joint assembly, P/N 19151749, ONLY after diagnosis concludes that it is an "inherent" rear axle noise and no physical damage or incorrect adjustment exists. Do NOT replace the propshaft assembly. If the noise is not correctly diagnosed as "inherent" and having a peak in the narrow speed range of 72-96 km/h (45-60 mph), the addition of a tuned damper slip yoke and u-joint can aggravate the perceptible noise level. It is extremely important to first diagnose the rear axle noise as "inherent". Refer to the following diagnostic information and procedure for rear axle noise in SI: Diagnostic Starting Point - Rear Drive Axle Symptoms - Rear Drive Axle Rear Drive Axle Noises Noisy in Drive Parts Information Warranty Information Page 5037 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 7175 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 16770 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 24033 Brake Light Switch: Locations Lighting Systems Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 7551 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 13610 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4522 10. Remove the rocker arm cover bolts. 11. Remove and discard the rocker arm cover bolt grommets, if necessary. 12. Remove the rocker arm cover. 13. Remove and discard the rocker arm cover gasket. 14. Clean and inspect the rocker arm cover, if necessary. Refer to Valve Rocker Arm Cover Cleaning and Inspection. Installation Procedure Important: Do not reuse the cover gasket or the valve rocker arm cover bolt grommets. 1. Install a NEW rocker arm cover gasket. 2. Install NEW rocker arm cover bolt grommets, if necessary. 3. Install the rocker arm cover. Page 24544 2009 Chevrolet Traverse 2007-2009 GMC Acadia 2007-2009 Saturn OUTLOOK 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood bussed electrical center (UBEC) is located in the engine compartment on the passenger side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. Note Remove the two relays next to the fuse to gain access to the fuse. 4. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Install the two relays removed in Step 4. 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 10. Secure the UBEC cover on the UBEC. 11. Close the hood. 12. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 13. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in Page 14055 10 - Retaining Clip 11 - SS1 Shift Spring 12 - SS1 Shift Valve 13 - Retaining Clip 14 - Control Main Spring 15 - Control Main Valve 16 - Shift Valve Body 17 - Shift Solenoid Retainer 18 - Shift Solenoid Screen 19 - SS1 20 - Shift Solenoid O-Ring 21 - Shift Solenoid O-Ring 22 - Manual Valve 23 - Manual Valve Pin Main Valve Body Assembly Disassembled Views Main Valve Body Assembly 1 - Main Valve Body Assembly 2 - Retaining Clip Page 4249 Notice: Refer to Fastener Notice. 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 N.m (62 lb in). Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. Install the tire on the wheel. Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 22478 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Diagram Information and Instructions Cruise Control: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 7886 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (7) from the camshaft position (CMP) sensor wiring harness jumper. 2. Remove the water pump. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor and wiring harness jumper from the engine front cover. 5. Disconnect the CMP sensor wiring harness jumper from the CMP sensor. 6. Remove the CMP sensor from the wiring harness jumper. Installation Procedure Page 185 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 13690 8. Depress the tangs and remove the cable from the range selector cable bracket. 9. Remove the cable clips from the floor panel reinforcement. 10. Remove the cable clips (2) from the transfer case, if equipped. 11. Lower the vehicle. 12. Ensure that the steering column shift lever is still in the park position. 13. Pull back the carpet and insulation around the driver's area. 14. Remove the instrument panel knee bolster. Page 6669 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 2609 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 3937 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 24100 6. Remove 100 mm (3.9 in) of harness tape, starting from the back of the connector, to make the repair. 7. Locate and remove the 240 circuit (red wire with white stripe) (1) from cavity E2. 8. Cut off the terminal. 9. Locate circuit 3040 (red wire with a white stripe) (2) located in cavity D1 of connector X1 and cut the 240 and 3040 wires 75 mm (3 in) from the back of the connector. Strip the ends of the wires. Page 18354 Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Page 21690 Power Door Lock Switch: Diagrams Vehicle Access Connector End Views Door Lock Switch - Driver (AU3 -AN3/DL3) Door Lock Switch - Passenger (AU3 -AN3/DL3) Page 8408 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 20054 Radio Front Speaker Replacement Radio Front Speaker Replacement Page 9116 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 23618 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 8938 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 10752 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 5833 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 5911 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 23130 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 16706 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15360 4. Install the boot over the end of the piston so the fold will face toward the brake caliper housing piston bore opening. Important: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Page 6769 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 9927 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 10180 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 13783 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 4903 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 3315 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. 3. Dismount the tire from the rim. Important: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 1878 Page 12752 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control Solenoid 1 (PCS1) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Page 2859 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 18000 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 143 Capacity Specifications Fluid - A/T: Capacity Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Capacity Specifications Pan Removal ....................................................................................................................................... ........................................................ 4.7 liters (5.0 qts) Overhaul .............................................................................................................................................. .................................................. 10.6 liters (11.0 qts) Dry Fill W/ 300 mm Torque Converter.................................................................................................. ............................................... 11.5 Liters (12.1 qts) Measurements are approximate Allison - Automatic Transmission Fluid Capacity Specifications Allison 1000 Initial Fill ............................................................................................................................................... ................................................. 12.0 liters (12.7 qts) Refill ..................................................................................................................................................... .................................................... 7.0 liters (7.4 qts) Measurements are approximate 6L50/6L80/6L90 - Automatic Transmission 6L80 Trans Pan Removal .................................................................................................................... ..................................................................... 5.7 liters (6.0 quarts) Overhaul Capacity ....................... ....................................................................................................................................................... 9.9 liters (10.5 quarts) Complete System Capacity ................................................................................... ............................................................................ 11.7 liters (12.4 quarts) 6L90 Trans Pan Removal .................................................................................................................... ..................................................................... 6.0 liters (6.3 quarts) Overhaul Capacity ....................... ....................................................................................................................................................... 9.9 liters (10.5 quarts) Complete System Capacity ................................................................................... ............................................................................ 11.7 liters (12.4 quarts) Approximate Capacities Page 3030 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 12678 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 11958 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 9469 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11618 Page 13475 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: * The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. * Apply the park brake. * The engine must start in the park (P) or neutral (N) positions only. * Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 1777 Page 20223 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 9342 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 14217 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle housing 2. Install the outer bearing into the wheel hub. 3. Install the outer bearing cup into the wheel hub. Page 14785 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16912 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 1338 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Page 16689 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 5505 10. Remove the water pump bolts. 11. Remove the water pump. 12. Remove and discard the water pump gaskets. 13. Clean and inspect the water pump, if necessary. Refer to Water Pump Cleaning and Inspection. Installation Procedure 1. If reusing the old fasteners, apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent to the threads of the water pump bolts. 2. Install NEW water pump gaskets and the water pump. Notice: Refer to Fastener Notice. 3. Install the water pump bolts. Tighten the bolts to 45 N.m (33 lb ft). 4. Using J 41240, hold the water pump pulley, install the water pump pulley bolts. Tighten the bolts to 25 N.m (18 lb ft). Interior - Front Power Seat Adjust/Memory Inoperative Power Seat Switch: Customer Interest Interior - Front Power Seat Adjust/Memory Inoperative Bulletin No.: 06-08-50-012 Date: October 06, 2006 TECHNICAL Subject: Front Driver or Passenger Power Seat Adjust Functions Inoperative and/or Driver Seat Memory Inoperative (Check Power Seat Switch Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (New Style), Suburban, Tahoe 2007 GMC Sierra (New Style), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the front driver or passenger power seat adjust functions are inoperative. They may also comment that the driver seat memory is inoperative. Cause The cause of this condition may be due to the power seat switch connector not being fully seated. Correction Remove the front seat cushion outer trim panel following the replacement procedure in SI. Verify that the power seat switch connector is fully seated. Reseat the connector and test the seat functions. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Brakes - Aftermarket Trailer Brake Controllers Trailer Brake Control Module: All Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 2793 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 16063 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 9776 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Description and Operation Electronic Throttle Actuator: Description and Operation Throttle Actuator Control (TAC) System Description Purpose The throttle actuator control (TAC) system delivers improved throttle response and greater reliability and eliminates the need for mechanical cable. The TAC system performs the following functions: * Accelerator pedal position sensing * Throttle positioning to meet driver and engine demands * Throttle position sensing * Internal diagnostics * Cruise control functions * Manage TAC electrical power consumption The TAC system includes the following components: * The accelerator pedal position (APP) sensors * The throttle body assembly * The engine control module (ECM) Accelerator Pedal Position (APP) Sensor The accelerator pedal contains 2 individual APP sensors within the assembly. The Accelerator Pedal Position (APP) sensors 1 and 2 are potentiometer type sensors each with 3 circuits: * A 5-volt reference circuit * A low reference circuit * A signal circuit The APP sensors are used to determine the pedal angle. The engine control module (ECM) provides each APP sensor a 5-volt reference circuit and a low reference circuit. The APP sensors provide the ECM with signal voltage proportional to the pedal movement. The APP sensor 1 signal voltage at rest position is less than 1 volt and increases to above 4 volts as the pedal is actuated. The APP sensor 2 signal voltage at rest position is near 0.5 volt and increases to more than 2 volts as the pedal is actuated. Throttle Body Assembly The throttle assembly contains the following components: * The throttle blade * The throttle actuator motor * The throttle position (TP) sensor 1 and 2 The throttle body functions similar to a conventional throttle body with the following exceptions: * An electric motor opens and closes the throttle valve. * The throttle blade is spring loaded in both directions and the default position is slightly open. * There are 2 individual TP sensors within the throttle body assembly. The TP sensors are used to determine the throttle plate angle. The TP sensors provide the engine control module (ECM) with a signal voltage proportional to throttle plate movement. The TP sensor 1 signal voltage at closed throttle is above 4 volts and decreases as the throttle plate is opened. The TP sensor 2 signal voltage at closed throttle is below 1 volt and increases as the throttle plate is opened. Engine Control Module The engine control module (ECM) is the control center for the throttle actuator control (TAC) system. The ECM determines the drivers intent and then calculates the appropriate throttle response. The ECM achieves throttle positioning by providing a pulse width modulated voltage to the TAC motor. Modes of Operation Normal Mode During the operation of the throttle actuator control (TAC) system, several modes or functions are considered normal. The following modes may be entered during normal operation: Page 9749 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 7016 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 3638 4. Loosen the air cleaner housing screws. 5. Lift up the air cleaner housing cover. 6. Remove the air filter element. Installation Procedure 1. Insert the NEW air filter element. 2. Install the air cleaner housing cover. Notice: Refer to Fastener Notice. 3. Tighten the air cleaner housing screws. Tighten the screws to 3 N.m (27 lb in). Page 14720 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 15934 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 1899 Vehicle Zoning Strategy Truck Zoning Page 11082 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 4893 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Service and Repair Compressor Clutch Hub: Service and Repair Compressor Clutch Plate/Hub Assembly Replacement (4.3L, 6.6L) Removal Procedure 1. Install a ratchet into the air conditioning belt tensioner adapter opening. 2. Rotate the belt tensioner counterclockwise in order to relieve the tension on the belt. 3. Remove the belt from the air conditioning (A/C) compressor. 4. Slowly release the tension on the A/C belt tensioner. 5. Remove the clutch plate retaining bolt (1). 6. Remove the clutch plate assembly (2). 7. Remove the clutch hub/bearing snap ring (3). 8. Remove the clutch hub/bearing assembly (4). 9. Remove the snap ring (5) from the clutch coil (6). 10. Remove the clutch coil (6) from the A/C compressor (7). Installation Procedure 1. Install the clutch coil (6) to the A/C compressor (7). 2. Install the snap ring (5) to the clutch coil (6). 3. Install the clutch hub/bearing assembly (4). 4. Install the clutch hub/bearing snap ring (3). 5. Place a small amount of oil on the thinnest air gap shim and place it inside the clutch plate. Page 24502 2. Locate the underhood bussed electrical center (UBEC) (1). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse (1). 4. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to Step 7 in this section of the bulletin 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 9. Secure the UBEC cover on the UBEC. 10. Close the hood. 11. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 12. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 Cadillac CTS 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Page 20330 Towing Hook / Bracket: Service and Repair Tow Hook Replacement (2500HD/3500 Series) Tow Hook Replacement (2500HD/3500 Series) Page 13539 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 22204 Front Center Seat Back Cushion Latch Replacement (AZ3) Front Center Seat Back Cushion Latch Replacement (AZ3) Page 13530 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 13831 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 14705 Page 16288 Junction Block - Right I/P X6 Generator Bracket Replacement Alternator: Service and Repair Generator Bracket Replacement Generator Bracket Replacement (4.3L) Removal Procedure 1. Remove the generator. 2. Remove the drive belt tensioner. 3. Remove the drive belt idler pulley. 4. Remove the generator bracket bolts and nut. 5. Remove the generator bracket. Installation Procedure 1. Install the generator bracket onto the stud. Page 11426 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 10651 4. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 N.m (80 lb in). 5. Install the fuel/EVAP line clip nut (2). Tighten the nut to 20 N.m (15 lb ft). 6. Remove the caps from the fuel and EVAP lines. 7. Connect the fuel tank EVAP line quick connect fitting to the chassis line. 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. 9. If equipped with 2WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle. 10. Install the fuel/EVAP line bracket locator tab to the frame. 11. Install the fuel/EVAP line clips to the frame and crossmember. 12. Install the fuel/EVAP line bracket bolt (2). Tighten the bolt to 9 N.m (80 lb in). 13. Install the fuel/EVAP line clip nut (1). Tighten the nut to 20 N.m (15 lb ft). 14. Remove the caps from the fuel and EVAP lines. 15. Connect the fuel tank EVAP line quick connect fitting to the chassis line. 16. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Page 11517 Vehicle Zoning Strategy Truck Zoning Page 11946 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 12120 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 15342 Page 1893 Door Lock and Side Window Switch Replacement - Driver Side Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Page 9661 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 16406 X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) (+U42) Page 8201 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure Page 24422 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 22967 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Remove the knock sensor heat shield bolt and shield. Page 7785 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 21812 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 136 Entertainment System Control Module: Service and Repair Audio System Transceiver Module Replacement Page 11101 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 19650 Navigation Software Update Procedure: Use the following procedure to update the Navigation Radio software using the Nav Software Update Disc P/N 25956121 (software version 0B92): This software update can only be used to update the navigation radios specified in this bulletin. DO NOT use this software to update any other vehicle's navigation radio. The Map DVD will be needed to verify the system operation after the software update has been performed. Use the vehicle's existing map DVD. It is recommended to wear latex gloves while performing the software update, to avoid fingerprints on the product and discs. DO NOT stop the engine until all tasks are completed. The software update MUST be performed with the engine RUNNING and the gear position in PARK. If the vehicle is turned off prior to the software update being completed, the process may not work again and a new Navigation Radio may be required. The software update requires using the map DVD slot. The update will not work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Start the engine, with the gear shifter in PARK - wait until the audio or caution screen is displayed after the opening screen. Press the "NAV" hard key. Press "OK" soft key. Press the "MENU" hard key. Press the "NAV" soft key. Press the "MAP DATABASE INFORMATION" soft key. Press the "CHANGE" soft key. The navigation radio automatically ejects the map DVD. Remove the ejected disc. Load the update disc into the slot located behind the display screen by inserting it partially until the system pulls it in. DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. The screen "PREPARING TO LOAD SYSTEM SOFTWARE" will be displayed while the update is loading. The update should take approximately 4 Page 9294 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 9359 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 4342 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 14723 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 5466 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 13254 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 6512 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 17424 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 9139 I/P Fuse Block Fuse: Locations I/P Fuse Block Fuse Block - I/P, Label Campaign - HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 15515 1. Lubricate all of the seals and the metal friction points with power steering fluid. 2. Install the accumulator (2) and the O-ring seal (3). 3. Place the J 26889 over the end of the accumulator. 4. Install the nut on the stud. 5. Depress the accumulator with a C-clamp. 6. Install the accumulator retainer ring (1). Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: Customer Interest Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14503 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 5769 Page 2474 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 19986 Page 14999 Control Module: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (MW7) 1 - Transmission Control Module 2 - Transmission Control Module Connector 3 - Radiator Fan Shroud Page 9635 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 7385 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 21434 Instrument Panel Compartment Door Latch Replacement (with RPO SLT) Instrument Panel Compartment Door Latch Replacement (with RPO SLT) Page 2898 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 15849 Page 9368 4. Connect the engine wiring harness electrical connector (4) to the CKP sensor. 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. 7. Perform the crankshaft position system variation learn procedure. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 14757 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 13555 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 15872 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 9529 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 3810 Refrigerant: Service and Repair Refrigerant Recovery and Recharging Tools Required * J 43600 ACR 2000 Air Conditioning Service Center * J 45037 A/C Oil Injector Caution: Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. Caution: For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Notice: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Notice: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Notice: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. Notice: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. the J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, Refer to Refrigerant System Capacities. Allison - Automatic Transmission Control Module: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Page 9014 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 9399 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 552 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12303 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 5302 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 21837 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 1945 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 16259 Fuse Block: Connector Views Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Top View Fuse Block - I/P, Bottom View Page 8482 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 16065 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 11304 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 22934 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 6499 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 3557 5. Install the appropriate spark plug wire boot(s) (1, 2) to the ignition coil. 6. Inspect the spark plug wires for proper routing (1, 2, 3, 4, 5, 6) and installation. 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 3. Any time the spark plug wire or boot are installed on the spark plug, new dielectric grease needs to be applied inside the boot. Page 2471 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 12039 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Disable the SIR system. 2. Remove the knee bolster. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. Page 11841 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 2407 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 252 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 9718 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 10435 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 15701 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Page 5390 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 10637 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Antilock Brake System Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure (W/JL4) Antilock Brake System Automated Bleed Procedure (With JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Using the scan tool, begin the automated bleed procedure. 4. Follow the instructions on the scan tool to complete the automated bleed procedure. Apply the brake pedal when instructed by the scan tool. 5. Turn the ignition OFF. 6. Remove the scan tool from the vehicle. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). 9. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 10. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 11. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 12. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 13. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes 14. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 15. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. (W/O JL4) Antilock Brake System Automated Bleed Procedure (Without JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Page 2076 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 23465 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Interior - Slit/Cut in Front Carpet/Rubber Covering Carpet: All Technical Service Bulletins Interior - Slit/Cut in Front Carpet/Rubber Covering Bulletin No.: 08-08-110-002 Date: February 11, 2008 INFORMATION Subject: Information on Slit or Cut in Front Floor Carpet or Rubber Floor Covering Under Drivers Seat Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2008 GMC Sierra (New Body Style), Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Carpet (RPO B30) or Rubber (RPO BG9) Floor Covering Some customers may comment on a slit or cut in the front floor carpet or rubber floor covering under the drivers seat. This slit is an access cut for servicing the inflatable restraint sensing and diagnostic module (SDM). The slit (1) is more noticeable when the seat track assembly is in the full rear position. DO NOT replace the front floor carpet or rubber floor covering. A service replacement carpet or mat will contain the same slit. Please inform your customer that the slit in the carpet or rubber floor covering is normal and provides service access to the inflatable restraint sensing and diagnostic module (SDM) (1). Page 24425 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8557 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 7113 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 7787 Page 3102 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 2754 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 9741 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 13927 2. Install the plug and O-ring into the converter housing. Tighten the plug to 12 N.m (108 lb in). Page 22891 2. Push the finishing lace (2) onto the track assembly flange (1) until fully seated around the sunroof opening. 3. Pull the finishing lace draw cord toward the sunroof opening. Remove the cord from the periphery of the opening. 4. Ensure that the finishing lace (2) is properly seated over the outer surface of the headliner (3). Page 17010 Page 10229 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 4931 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 11243 Page 12662 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 15789 11. Remove the generator bolts. 12. Reposition the heater outlet, and AC compressor/condenser hoses as necessary in order to remove the generator. 13. Remove the generator from the generator bracket. Installation Procedure 1. Install the generator into the generator bracket. 2. Position the heater outlet, and AC compressor/condenser hoses as necessary. Notice: Refer to Fastener Notice. 3. Install the generator bolts. Tighten the bolts to 50 N.m (37 lb ft). Page 2974 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 14890 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 24536 the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers/retailers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. Parts Information No parts are required for this recall. Customer Reimbursement - For GM US All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Note (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada and Export Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by June 8, 2011. All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of repair expense(s) that were not reimbursed, a description of the repair, and the person or entity performing the repair. Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS or GWM. Note Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification. Customer Reimbursement - For Saturn US Only All customer requests for reimbursement for previous repairs for the recall condition are handled by submitting a recall reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center. A Saturn Customer Reimbursement Procedure and Claim Form are included with the customer letter. Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - submit as Net Item under the repair labor code. Page 19644 8. The navigation radio automatically ejects the map DVD. Remove the ejected disc. Important DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. 9. Load the update disc into the slot located behind the display screen by inserting it partially until the system pulls it in. 10. The screen "PREPARING TO LOAD SYSTEM SOFTWARE" will be displayed while the update is loading. The update should take approximately 4 minutes. 11. After the system restarts, press the "EJECT" soft key to eject and remove the software update disc. Important Dealers should retain the software update disc for their use. 12. Load the map DVD into the same slot located behind the display screen, DO NOT put in the top slot. 13. Press the "CLOSE" soft key. 14. Press the "OK" soft key. 15. Press the "MENU" hard key. Important The clock will not be displayed until it is confirmed by completing step 16. 16. Turn the engine OFF. Open and close the driver's door. Wait for 10 minutes. Important Due to the load time of the system, there may be a short delay before the "Map Screen" appears. 17. Restart the engine. After the map screen is displayed, verify that the clock is visible and touch the map screen to confirm that it can be scrolled. If the clock does not appear, repeat programming. Important The GPS location will start out in Washington DC and once learned, will show the correct location of the vehicle. Learning the GPS may take up to 10 minutes, depending on the vehicle's location. 18. Ensure that the GPS signal has been received and the navigation map shows the correct location for the vehicle. 19. Verify that the destination search area is properly displayed. 1. Press the "DESTINATION" hard key. 2. Press "CHANGE SEARCH AREA" soft key. 3. Select the correct area for the vehicle's location. Warranty Information Page 218 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 17994 Important: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 3. Mount the tire to the rim. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 7437 Fuel Pressure: Service Precautions Relieving Fuel Pressure Caution Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 1944 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2809 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 23542 Page 3375 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 3919 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 2613 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 1141 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12146 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 11971 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 18789 Page 22338 Rear Seat Cushion Cover and Pad Replacement (Extended Cab with A68) Page 541 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 24505 14. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 HUMMER H2 1. Open the hood and disconnect negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block in the engine compartment is located on the driver side of the vehicle near the battery. Lift the cover for access to the fuse/relay block. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. 4. Remove the two relays next to the fuse to gain access to the fuse. 5. Remove the 60 amp heated windshield washer fuse using needle-nose pliers. 6. Discard the 60 amp heated windshield washer fuse. 7. Install the two relays removed in Step 4. 8. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 9 in this section of the bulletin. 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 10. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 14. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this bulletin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. 2008-2009 Buick Enclave Page 9446 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 17669 5. Exert a 110 N.m (25 lb) force upward and then downward while measuring the total distance the idler arm moves. 6. If the movement exceeds 2 mm (0.078 in) then replace the idler arm. Page 19801 - 15882767 - 15940102 - 15940103 - 25797978 - 25834072 Update the Navigation Radio's software to correct this condition. This software upgrade will also update some operating characteristics on the Navigation Radio. The following functions or displays may be affected: Important Inform the customer that stored destinations and radio presets may not be retained during programming. - Clock font size - Text color on light colored screens - Split screen icon to minimize the "Points of Interest" popup and "Exit" popup - Destination keyboard characters moved from page 2 to page 1. - "Back" button on street address entry screen for entering street number - User selectable lock-outs for XM Categories, music Navigator, MP3 folders, address book, POI's and Turn list. - "I Agree" screen changed from every ignition cycle to once in every 50 ignition cycles. - Screen Brightness adjustment not disabled while vehicle is in motion. How to Obtain Nav Software Update Disc (P/N 25956121 - software version 0B92): Software discs are available through the GM Nav Disc Center. Dealers should treat the disc like a special tool and retain the disc for use in repairing future vehicles. DO NOT give the software disc to the customer. Navigation Software Update Procedure: Use the following procedure to update the Navigation Radio software using the Nav Software Update Disc P/N 25956121 (software version 0B92): Important - This software update can only be used to update the navigation radios specified in this bulletin. DO NOT use this software to update any other vehicle's navigation radio. - The Map DVD will be needed to verify the system operation after the software update has been performed. Use the vehicle's existing map DVD. - It is recommended to wear latex gloves while performing the software update, to avoid fingerprints on the product and discs. The software update requires using the map DVD slot. The update will not work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Notice DO NOT stop the engine until all tasks are completed. The software update MUST be performed with the engine RUNNING and the gear position in PARK. If the vehicle is turned off prior to the software update being completed, the process may not work again and a new Navigation Radio may be required. 1. Start the engine with the gear selector in PARK. Wait until the audio or caution screen is displayed after the opening screen. 2. Press the "NAV" hard key. 3. Press "OK" soft key. 4. Press the "MENU" hard key. 5. Press the "NAV" soft key. 6. Press the "MAP DATABASE INFORMATION" soft key. 7. Press the "CHANGE" soft key. Page 9744 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 14153 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17-21 mm (0.6-0.8 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 in) below the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Notice: Refer to Fastener Notice. 8. Install the rear axle fill plug and gasket. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (9.5LD Inch Axle) Rear Axle Lubricant Level Inspection (9.5LD Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Notice: Refer to Fastener Notice. 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (9.5 Inch HD and 10.5 Inch Axles) Rear Axle Lubricant Level Inspection (9.5 Inch HD and 10.5 Inch Axles) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. Page 15564 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 14032 Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Inch) Disclaimer Page 10739 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 5849 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1997 Page 7384 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 17202 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 2739 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 22039 Disclaimer Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 4277 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 10467 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 24141 Important: Use a NEW steering shaft lock plate retaining ring. 1. Install the following parts onto the steering shaft: 1. Lubricate the turn signal switch cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam position plate (2) 3. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137. 2. Install the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Page 2391 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 15737 14. Install the battery current sensor (3) clip to the battery tray. 15. Connect the engine wiring harness electrical connector (1) to the battery current sensor. 16. Install the air cleaner outlet resonator. 17. Connect the negative battery cable. Page 10221 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 14332 Seals and Gaskets: Service and Repair Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Tools Required * J 8092 Universal Driver Handle - 3/4 inch - 10 * J 2222-C Wheel Bearing Nut Wrench * J 24426 Wheel Bearing Race Installer - Outer * J 24427 Wheel Bearing Race Installer - Inner * J 44419 Hub Outer Bearing Race Installer * J 44420 Differential Bearing and Hub Seal Installer Removal Procedure Important: The wheel hub seal must be replaced anytime the wheel hub assembly is removed from the axle housing. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper bracket. It is not necessary to remove the brake caliper from the bracket. 4. Remove the axle shaft. 5. Remove the axle nut retaining ring. 6. Remove the key. 7. Remove the adjusting nut using the J 2222-C. Page 493 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 5157 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10987 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 8484 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 8055 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 18770 1 - Lower Radiator Support 2 - Inflatable Restraint Front Sensor Under the Front Seats Page 11567 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 20439 Disclaimer Page 11214 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 13961 ^ Inspect transmission filter for any cracks, holes or split seams that may allow air to be sucked into the pump. ^ Inspect the check balls for roundness ensuring that there are no flat spots. ^ Measure all the valve body bore plugs (328) for diameter. The specification is 11.502 mm +/0.004 mm. Undersize bore plugs should be replaced. ^ Inspect clutch select valve 2 (352) (Closest to the manual valve) in the lower valve body (351) for freedom of movement and travel. ^ Inspect CBR1/ C456 Reg Valve (327) in the upper valve body (321) for freedom of movement and travel. ^ Perform Control Solenoid Valve and Transmission Control Module Assembly Solenoid Performance Test (SI Document ID # 1618572) to determine if shift solenoid # 1 is functioning properly. Important: The seals included in plate kit, P/N 24236934, should be replaced when the valve body is assembled. Do not reuse the old seals. ^ Replace the spacer plate with P/N 24245720. This spacer plate makes use of a revised gasket to help reduce the occurrence of DTC P0751. Page 15797 1. Install the ignition lock cylinder case (1) to the vehicle. Notice: Refer to Fastener Notice. 2. Install the 3 ignition lock cylinder case screws (2). Tighten the screws to 7 N.m (62 lb in). 3. Install the park lock cable into the lock cylinder housing. 4. Connect the passlock and key buzzer to the ignition lock cylinder case. 5. Install the ignition/start switch. 6. Install the inflatable restraint steering wheel module coil. Page 12912 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (367A) and the 1-2 shift solenoid retainer (395). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. 4. Install the pressure control solenoid (377). Notice: Refer to Fastener Notice. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Page 4287 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 9199 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 11867 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 4113 Fuse Block: Connector Views Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Top View Fuse Block - I/P, Bottom View Page 7856 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 7969 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 15616 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 630 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 8569 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 10402 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 10805 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 22495 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 23313 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 6645 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 10085 4. Connect the EVAP vent solenoid pipe quick connect fitting (3) to the EVAP canister. 5. Install the EVAP canister vent solenoid pipe clip (1) to the frame crossmember. 6. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid. 7. Install EVAP canister vent solenoid clip (1) to the chassis EVAP line. 8. Install the EVAP canister vent solenoid pipe to the clip (2) on the chassis EVAP line. 9. Install the EVAP canister vent solenoid pipe to the clips (3) on the brake pipes. 10. Lower the vehicle. Allison - Automatic Transmission Pressure Regulating Solenoid: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Mod Main Pressure Control Solenoid Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Page 24620 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Page 12395 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 15873 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 12929 Page 7780 Page 18430 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Interior HVAC Module 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 16217 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Drive Pinion Housing and/or Seal Replacement Pinion Gear: Service and Repair Drive Pinion Housing and/or Seal Replacement Drive Pinion Housing and/or Seal Replacement Tools Required * J 44414 Pinion Seal Installer * J 22912-B Bearing Puller * J 24433 Pinion Cone and Side Bearing Installer * J 37624 Pinion Bearing Installer * J 8092 Driver Handle * J 8608 Rear Pinion Bearing Race Installer * J 8614-01 Flange/Pulley Holding Tool Removal Procedure Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the axle lubricant. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 3. Remove the axle shafts. 4. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 5. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 6. Measure the amount of torque required to rotate the pinion and the ring gear. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion pilot bearing * The pinion oil seal * The differential case bearings Page 15313 Brake Shoe: Testing and Inspection Brake Shoe Inspection Inspect the linings every 9 650 km (6,000 mi) and any time the wheels are removed (tire rotation, etc.). Inspect the lining for wear by removing the plug and using the inspection hole. Replace the shoe and lining assemblies when the thickness of any lining is worn within 0.72 mm (0.030 in) of the shoe. Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.030 in) of any rivet head. Always replace shoe and lining assemblies as a complete axle set. Page 1916 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12188 Page 14817 Tighten the bolt to 11 N.m (97 lb in). 6. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 9. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 17709 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Page 19581 Entertainment System Control Module: Diagrams Entertainment/Communication Connector End Views Infrared Module (U42) Page 23387 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 13541 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 16685 Page 3349 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 10581 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 4895 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 2955 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 19407 Disclaimer Page 18200 Page 4068 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 10211 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 22371 For vehicles repaired under warranty, use the table. Disclaimer Page 9162 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - Step 7 Page 8174 Engine Control Module X1 (Pin 25 To 73) Engine Control Module X2 Page 14242 1. Install the axle shaft bearing using the J 23690 (8.6 inch and 9.5 inch LD axles) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128 (8.6 inch and 9.5 inch LD axles) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 9. Lower the vehicle. Page 16051 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 5049 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 16737 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 5893 Page 9793 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Instrument Panel Electrical Center or Junction Block Replacement - Left Side Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Left Side Instrument Panel Electrical Center or Junction Block Replacement - Left Side Page 12108 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Specifications Connecting Rod Bearing: Specifications Connecting Rod Connecting Rod Bearing Clearance - Production ...................................................................................................... 0.038-0.078 mm 0.0015-0.0031 in Connecting Rod Bearing Clearance - Service ............................................................................................................ 0.025-0.063 mm 0.0010-0.0025 in Page 12944 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 4108 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 13544 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 15840 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 8265 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Wipers/Washers - Washer Fluid Leak on The Driver's Side Windshield Washer Pump: All Technical Service Bulletins Wipers/Washers - Washer Fluid Leak on The Driver's Side INFORMATION Bulletin No.: 08-08-43-006 Date: April 08, 2008 Subject: Information on Windshield Washer Solvent Leaking Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali If a customer comments that there is windshield washer solvent leaking from the front drivers side of the vehicle this condition may be caused by a cut or not properly seated washer pump grommet. Before replacing the washer pump inspect the condition of the grommet around the inlet of the washer pump. First make certain that the pump/grommet is fully seated in the washer solvent container. If a leak still exists then remove the pump from the container using care not to tear or cut the grommet during removal and inspect the grommet to make sure it's free of cuts or tears. Install the pump and grommet back into the container making sure to use washer solvent to lubricate the grommet. Inspect for leaks again. If the washer solvent still leaks be sure to inspect the outlet hose for a proper connection. Make every effort to inspect all components before ordering a new part. DO NOT replace the washer pump unless you see that the pump is cracked or broken externally. If the grommet is torn or cut replace only the grommet. Disclaimer Brakes - Aftermarket Trailer Brake Controllers Trailer Brake Control Module: All Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 11603 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 17089 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 10669 Fuel Return Line: Service and Repair Fuel Hose/Pipes Replacement - Engine Compartment Fuel Hose/Pipes Replacement - Engine Compartment Removal Procedure Important: Clean all the fuel pipe connections and surrounding areas before disconnecting the pipe in order to avoid possible fuel system contamination. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the chassis fuel feed pipe (1) from the engine compartment feed pipe. 4. Remove the fuel pipe retainer nuts (1). 5. Remove the fuel pipe bracket bolt (2). Page 23348 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice. 2. Install the park brake warning lamp switch bolt. Tighten the bolt to 3 N.m (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. 5. Connect the negative battery cable. Page 18788 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Inflatable Restraint Side Impact Sensor Replacement (Extended Cab) Page 5843 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Specifications Brake Pad: Specifications Brake pad wear limit ............................................................................................................................ .................................................. 0.76 mm (0.030 in) Page 14060 Lower Control Valve Body Assembly Disassembled Views (6L80) Lower Control Valve Body Assembly 323 - Retainer 328 - Clutch Regulator Valve Bore Plug 338 - Shuttle Valve 351 - Control Valve Lower Body 352 - Clutch Select Solenoid Valve 353 - Clutch Select Solenoid Valve Spring 354 Manual Valve 355 - TCC Regulator Apply Valve 356 - Clutch Piston Dam Feed Regulator Valve 357 - Clutch Piston Dam Feed Regulator Valve Spring Control (With Body and Valve) Valve Assembly Disassembled Views (6L90) Page 21820 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 4083 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 5841 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 14351 Wheel Hub: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Page 9885 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 6309 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 6593 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 23835 Close the passenger door. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7853 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 9765 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 3431 1 - Door Frame 2 - Window Switch - Left Rear (A31) 3 - Window Motor - Left Rear (A31) 4 Speaker - Left Rear Door 5 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 6 Door Latch Assembly - Left Rear Right Rear Door (Crew Cab) Page 24312 Sliding Rear Window - Switch (A48) Page 11384 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 17671 Idler Arm: Service and Repair Idler Arm Replacement Tools Required J 24319-B Steering Linkage and Tie Rod Puller Removal Procedure Notice: Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result. Use the proper tool to separate all ball joints. 1. Remove the engine shield, if equipped. Important: Discard the idler arm nut. 2. Remove the idler arm nut (3) from the idler arm (1). 3. Separate the idler arm (1) from the relay rod (2). 4. Remove the idler arm from the relay rod using puller J 24319-B. Page 1853 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 4964 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 12505 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Disable the SIR system. 2. Remove the knee bolster. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. Page 12816 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 24185 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 22931 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 1903 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 11941 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 15627 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 6290 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 14333 8. Remove the adjusting nut. 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. Page 15961 Page 24318 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Crew Cab) Rear Side Door Window Switch Replacement (Crew Cab) Page 6820 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Page 15829 11. If replacing the starter, remove the starter heat shield. Installation Procedure 1. If the starter was replaced, install the starter heat shield to the starter. 2. Position the starter to the vehicle. Locations Electronic Brake Control Module: Locations Antilock Brake System Component Views Left Side of the Engine Compartment 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (- MYC) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Page 3782 5. Remove the rear axle fill plug and the seal. 6. Inspect the lubricant level. The lubricant level should be between 17-21 mm (0.6-0.8 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is between 17-21 mm (0.6-0.8 in) below the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Notice: Refer to Fastener Notice. 8. Install the rear axle fill plug and gasket. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (9.5LD Inch Axle) Rear Axle Lubricant Level Inspection (9.5LD Inch Axle) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Notice: Refer to Fastener Notice. 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 9. Lower the vehicle. Rear Axle Lubricant Level Inspection (9.5 Inch HD and 10.5 Inch Axles) Rear Axle Lubricant Level Inspection (9.5 Inch HD and 10.5 Inch Axles) 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Make sure the vehicle is level. 3. Inspect the rear axle for leaks. Repair as necessary. 4. Clean the area around the rear axle fill plug. Page 16792 Auxiliary Power Outlet: Tools and Equipment Special Tools Page 22216 Page 24706 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 5187 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 23696 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (without RPO SLT) Fog Lamp Switch Replacement (without RPO SLT) Page 5804 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 9537 Page 8379 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 16211 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Page 5103 Vehicle Zoning Strategy Truck Zoning Page 7330 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 19709 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Page 23843 For vehicles repaired under warranty, use the table above. Disclaimer Page 6351 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 11424 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 9847 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 13870 Transmission Cooler: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Notice: Refer to Fastener Notice. 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 N.m (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. 4. Install the front grill assembly. Page 19364 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2595 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 2956 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 11799 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 24361 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8313 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 7525 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8-11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8-11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kpa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. * Normal The compression builds up quickly and evenly to the specified compression. * Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. * Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Page 17329 X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (AZ3/D07 +UQ3) Page 5404 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Restraints/Interior - Front Seat Belt Twisted Seat Belt: All Technical Service Bulletins Restraints/Interior - Front Seat Belt Twisted TECHNICAL Bulletin No.: 07-09-40-001A Date: May 14, 2009 Subject: Front Seatbelt Latch Plate Reversed, Front Seatbelt Twisted (Perform Repair to Untwist Seatbelt) Models: 2008-2009 Buick Enclave 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2009 Saturn OUTLOOK .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to add the Traverse model and the 2009 model year. Please discard Corporate Bulletin Number 07-09-40-001 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. Condition Some customers may comment that the seatbelt latch plate is reversed on the belt webbing or that they have to twist the webbing before buckling the seatbelt. This condition can be visually verified by inspecting the location of the latch plate tongue. If the tongue is between the webbing and the pillar post, it is reversed. Correction Do NOT replace the seatbelt retractor for this condition. To correct this condition, perform the following repair. 1. Pull the majority of the belt webbing out of the retractor. 2. With the latch plate resting at its lowest point, take the webbing above the latch plate and fold the webbing over itself at a 45 degree angle. Pinch the folded portion between the thumb and forefinger. 3. Using the other hand, pull the latch plate up over the fold until past the doubled over section. Page 8516 Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 3. Remove the fuel pump/oil pressure sensor fitting, if necessary. Installation Procedure 1. If installing the old fitting, apply sealant to the threads of the fitting. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 2. Install the fitting until snug, if necessary. Notice: Refer to Fastener Notice. 3. Tighten the fuel pump/oil pressure sensor fitting. 1. Tighten the fitting to 15 N.m (11 lb ft). 2. Increase torque until the centerline of the fitting (1) is 50 degrees from the centerline of the crankshaft (2). Page 3755 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 16889 Interior - Front Seat Cushion Cover Becomes Detached Seat Cushion: Customer Interest Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Page 22989 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 8018 Data Link Connector: Testing and Inspection Data Link References This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. Some modules may have multiple communication circuits passing through them without actively communicating on that data link. This table is used to assist in correcting a communication malfunction. For the description and operation of these serial data communication circuits refer to Data Link Communications Description and Operation. Page 3916 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 7375 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 4684 19. Remove the positive crankcase ventilation (PCV) valve hose from the valve cover and rocker cover. 20. Disconnect the power brake booster vacuum hose from the vacuum fitting. 21. Reposition the radiator inlet hose clamps. 22. Remove the radiator inlet hose from the thermostat housing. 23. Reposition the water pump inlet hose clamps. 24. Remove the water pump inlet hose. 25. In order to remove the front intake manifold bolt, perform the following: 1. Remove the drive belt. 2. Loosen the power steering (P/S) pump rear bracket nut. 3. Remove the P/S pump rear bracket front nut. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 11289 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Allison - Automatic Transmission Transmission Speed Sensor: Service and Repair Allison - Automatic Transmission Speed Sensor Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Page 7231 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 22990 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 12076 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10377 Page 9048 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: Recalls Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 2930 Page 14615 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 20577 Page 14741 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 20578 Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Brace Replacement Rear Bumper Impact Bar Brace Replacement TRLR RT STOP/TURN PCB Relay Brake Lamp Relay: Locations TRLR RT STOP/TURN PCB Relay Electrical Center Identification Views Fuse Block - Underhood, Label Page 2037 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 9686 4. Connect the engine wiring harness electrical connector (1) to the HO2S pigtail electrical connector. 5. Connect the CPA retainer. 6. Lower the vehicle. Turn Signal Multifunction Switch Replacement Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Page 3376 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 19110 1 - Outside Rearview Mirror - Passenger 2 - Door Lock Switch - Passenger (AU3 -AN3/DL3) 3 Passenger Door Switch (PDS) (AN3/DL3) 4 - Door Latch Assembly - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) 6 - Speaker - Right Front 7 - Window Motor - Passenger (A31) 8 - Window Switch - Passenger (A31 -AN3/DL3) 9 - Heated Seat Switch Passenger (AN3) Left Rear Door (Extended Cab) A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 6835 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Page 9717 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 5799 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 22770 Parts Information The service replacement latch kit will include one latch, one left rail end cover and one right rail end cover as shown in the illustration above. Use the latch with the appropriate rail end cover and discard the extra cover. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 23953 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 3383 Transmission Mode Switch: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Internal Mode Switch (IMS) Internal Mode Switch (IMS) Page 22769 Pull the latch assembly in to gain access to the outer Allen head set screw (1). Loosen the Allen head set screw. Slide the outer set screw and nut assembly (1) out from the rail track. Slide the old latch and spring assembly out of the rail. Slide in the new pull strap latch assembly into the rail track. Install the outer Allen set screw and nut assembly into the rail track. Tighten the set screw. Install the new rail end cover. Roll the tonneau cover up toward the front of the truck bed. Release the right front pull strap latch assembly. Remove the tonneau cover from the side rails. Access the right front pull strap latch assembly. Remove the right front plastic rail end cover from the right front tonneau cover rail. Replace the right front pull strap latch assembly by repeating steps 5-12. Reinstall the tonneau cover. Page 1754 Turn Signal/Malfunction Switch X3 Page 6936 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 9899 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 11881 Page 221 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 13342 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 13974 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 10414 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 5991 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 14740 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 6944 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 7647 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 3186 Air Bag Deactivation Switch: Service and Repair Inflatable Restraint Instrument Panel Module Disable Switch Replacement Page 1047 Engine Control Module X2 (Pin 1 To 30) Page 16878 Fuse: Locations Left I/P Junction Block Junction Block - Left I/P, Label Junction Block - Left I/P, Device Usage Page 11300 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. OnStar(R) - Availability for Hearing Impaired Navigation System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 19631 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 6515 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 11011 Page 16129 Page 5323 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 20384 Trailer Connector: Diagrams Power and Grounding Connector End Views Trailer Connector (UY7) Page 6531 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 20697 Front Door Latch: Diagrams Vehicle Access Connector End Views Door Latch Assembly - Driver (AU3) Door Latch Assembly - Driver (-AU3) Page 2227 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 15901 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 7390 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 17141 Page 19914 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Page 2481 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 20198 Method 1 Method 2 Page 8210 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 13742 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 14863 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 21559 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Diagrams Brake Fluid Pressure Sensor/Switch: Diagrams Brake Master Cylinder Pressure Sensor (JL1) Brake Master Cylinder Pressure Sensor (JL1) Page 24234 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 6943 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Electrical - Multiple Electrical Concerns Wiring Harness: Customer Interest Electrical - Multiple Electrical Concerns Bulletin No.: 07-08-49-018 Date: September 07, 2007 TECHNICAL Subject: Various Electrical Concerns - Intermittently Functioning or Inoperative Component, IP Warning Light On, DIC Message Displayed, DTC Set, No Crank/Start (Repair IP Wiring Harness) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on one of the driver notifications and/or effects shown above. Page 16791 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Locations Ignition Control Module: Locations Engine Controls Component Views Rear of the Engine 1 - Central Sequential Fuel Injection (SFI) Module 2 - Manifold Absolute Pressure (MAP) Sensor 3 G106 4 - Engine Oil Pressure (EOP) Sensor 5 - Ignition Control Module (ICM) 6 - G107 Page 8389 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 18718 2. Move the driver's seat to the full forward or rearward position. Carpet and cutout flap (2) shown with the driver's seat removed from the vehicle for illustration purposes only. Seat removal is NOT required to gain access to the acoustical pad (3). 3. Lift the cutout flap (2) in the carpet or vinyl to gain access to the acoustical pad (3) that covers the SDM. Seat removed for illustration purposes only. 4. Using your hand, tear away and remove the acoustical pad (3) that covers the SDM (4). Ensure that no acoustical pad remains over, or in contact with, the SDM (4). 5. Lower the carpet or vinyl cutout flap over SDM (4) and adjust the driver's seat to the customer-desired position. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. Page 22008 Sunroof / Moonroof Drain: Service and Repair Sunroof Housing Front Drain Hose Replacement Sunroof Housing Front Drain Hose Replacement Removal Procedure 1. Remove the instrument panel trim. Important: It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to gain access. 2. It is only necessary to lower the headliner. Only do those steps in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Regular Cab) Headlining Trim Panel Replacement (Extended Cab) Headlining Trim Panel Replacement (Crew Cab). 3. Disconnect the front sunroof drain hose from the sunroof module front spigot, right or left side, as needed. 4. Remove the 1 hose clips securing the drain hose to the windshield pillar, right or left side, as needed. 5. Remove the drain hose from the vehicle, right or left side, as needed. Installation Procedure 1. Install the drain hose by passing it threw the front of the dash panel. 2. Route the end of the drain hose through side cowl panel until the paint mark is visible, right or left side, as needed. 3. Install the 1 hose clips securing the drain hose to the side door frame, right or left side, as needed. Page 11979 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 2316 4. If installing the old sensor, apply sealant to the threads of the sensor. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 5. Using J 41712, install the sensor. Tighten the sensor to 30 N.m (22 lb ft). 6. Connect the fuel pump/oil pressure sensor electrical connector (3). 7. Check and adjust the engine oil level, if necessary. Page 8158 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 9714 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 23963 Marker Lamp: Service and Repair Roof Marker Lamp Replacement (Minus SRW) Roof Marker Lamp Replacement (Minus SRW) Page 16724 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Diagrams Headlamp Switch: Diagrams Lighting Systems Connector End Views Headlamp and Panel Dimmer Switch Page 5811 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 14837 Vehicle Zoning Strategy Truck Zoning Page 3098 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 7981 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 7037 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 11519 Knock Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch Page 24714 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 8994 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 5128 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11933 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 9754 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 8411 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 8701 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 15266 Brake Rotor/Disc: Specifications Front Brakes JF3, JF7 Rotor Discard Thickness * ................................................................................................................... .................................................. 28.0 mm 1.10 in Rotor Minimum Allowable Thickness After Refinish ............................................................................................................................ 28.0 mm 1.10 in Rotor Thickness (new) ............................................................................................................. ............................................................ 30.0 mm 1.181 in Rotor Maximum Allowable Lateral Runout ......................................................................................................................................... 0.05 mm 0.002 in Rotor Maximum Allowable Scoring......................................................................................... ............................................................. 1.50 mm 0.059 in Rotor Maximum Allowable Thickness Variation ............................................................................................................................... 0.025 mm 0.001 in Front Brakes JD9, JH6, JH7 Rotor Discard Thickness * ................................................................................................................... .............................................. 36.50 mm 1.437 in Rotor Minimum Allowable Thickness After Refinish ........................................................................................................................... 37.0 mm1.457 in Rotor Thickness (new) ..................................................................................................... .................................................................... 38.0 mm 1.496 in Rotor Maximum Allowable Lateral Runout ......................................................................................................................................... 0.13 mm 0.005 in Rotor Maximum Allowable Scoring .................................................................................................................................................... 1.50 mm 0.059 in Rotor Maximum Allowable Thickness Variation ............................................................................................................................... 0.025 mm 0.001 in Rear Brakes JD9 Rotor Discard Thickness * ................................................................................................................... ................................................ 18.0 mm 0.709 in Rotor Minimum Allowable Thickness After Refinish ........................................................................................................................ 18.5 mm 0.7282 in Rotor Thickness (new) ......................................................................................................... ................................................................ 20.0 mm 0.787 in Rotor Maximum Allowable Lateral Runout ......................................................................................................................................... 0.25 mm 0.010 in Rotor Maximum Allowable Scoring ................................................................................................................................................... 1.50 mm 0.059 in Rotor Maximum Allowable Thickness Variation ............................................................................................................................. 0.009 mm 0.0004 in Rear Brakes JH6 Rotor Discard Thickness * ................................................................................................................... ................................................ 27.5 mm 1.083 in Rotor Minimum Allowable Thickness After Refinish .......................................................................................................................... 28.0 mm 1.102 in Rotor Thickness (new) ........................................................................................................... .............................................................. 30.0 mm 1.181 in Rotor Maximum Allowable Lateral Runout ......................................................................................................................................... 0.13 mm 0.005 in Rotor Maximum Allowable Scoring .................................................................................................................................................... 1.50 mm 0.059 in Rotor Maximum Allowable Thickness Variation ............................................................................................................................... 0.025 mm 0.001 in Rear Brakes JH7 Rotor Discard Thickness * ................................................................................................................... ................................................ 28.5 mm 1.122 in Rotor Minimum Allowable Thickness After Refinish ............................................................................................................................ 29.0 mm 1.142 in Rotor Thickness (new) ........................................................................................................... .............................................................. 30.0 mm 1.181 in Rotor Maximum Allowable Lateral Runout ......................................................................................................................................... 0.13 mm 0.005 in Rotor Maximum Allowable Scoring .................................................................................................................................................... 1.50 mm 0.059 in Rotor Maximum Allowable Thickness Variation ............................................................................................................................... 0.025 mm 0.001 in * All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace any rotor that does not meet the minimum thickness specifications. Page 6361 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 1826 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 9783 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 2565 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: * The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. * Apply the park brake. * The engine must start in the park (P) or neutral (N) positions only. * Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 7643 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 13145 Control Module: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (MW7) 1 - Transmission Control Module 2 - Transmission Control Module Connector 3 - Radiator Fan Shroud Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 5969 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 2887 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9849 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 1016 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Locations Wheel Speed Sensor: Locations Antilock Brake System Component Views Front Sensors 1 - Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7/JH6/JH7) 2 - Chassis 3 - Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7/JH6/JH7) Rear Sensors Page 13792 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Locations Exterior Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 528 Page 17691 Notice: Refer to Fastener Notice. 2. Install the power steering fluid cooler bolts (2) to the power steering fluid cooler (1). Tighten the bolts to 9 N.m (80 lb in). 3. Connect the power steering fluid cooler hose (3) to the power steering pump (1). 4. Connect the power steering gear outlet hose (2) to the power steering fluid cooler (4). 5. Clean any excess fluid from the vehicle and remove the drain pans. 6. Fill and bleed the power steering system. 7. Install the radiator grille. Page 223 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 16993 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 14028 Page 8802 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 20912 Note Using the punch and hammer, strike the rounded end of the roll pin to loosen the roll pin. The head of the roll pin should protrude from the handle housing. Remove the roll pin with pliers as shown in the illustration. 3. Using a punch, hammer, and pliers, remove the roll pin from the inside door handle. 4. Discard the roll pin. 5. Install the new roll pin that is included in the door handle kit, P/N 88880051. 6. Install the front side door inside handles. Refer to Front Side Door Inside Handle Replacement in SI. Rear Side Door Inside Handle Replacement 1. Remove the driver and passenger rear side door inside handles. Refer to Rear Side Door Inside Handle Replacement in SI. 2. Place rear side door inside handles on a work bench. Note Using a punch and hammer, strike the rounded end of the roll pin to loosen the roll pin. The head of the roll pin should protrude from the handle housing. Remove the roll pin with pliers as shown in the illustration. 3. Using a punch, hammer, and pliers, remove the roll pin from the inside door handle. 4. Discard the roll pin. Page 13439 Tighten the bolt to 11 N.m (97 lb in). 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. Tighten the bolts to 11 N.m (97 lb in). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Locations Battery Current Sensor: Locations Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor Page 15212 Page 5424 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 3959 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 1888 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Page 9338 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 24250 Page 2994 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 12259 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 5164 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 261 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 16881 Page 1381 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 20850 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 6042 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 24247 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 4887 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 5465 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 9496 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 14172 9. Place an alignment mark between the pinion and the pinion yoke. 10. Install the J 8614-01 as shown. 11. Remove the pinion nut while holding the J 8614-01. 12. Remove the washer. 13. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 14. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. 15. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388 (8.6 inch, 9.5 inch axles) or the J 44414 (10.5 inch, 11.5 inch axle). 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. Page 3175 4. Reposition the knock sensor sleeve (2) down, away from the knock sensor. 5. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. 6. Remove the knock sensor bolt and sensor. Installation Procedure Page 13794 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 16571 The IP wiring branch to C202 (IP to body cam lock connection) may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been seated. Possible point of contact (2). The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been seated. Possible points of contact (1, 2). The IP wiring branch to C202 may have never been secured into place (gray retaining clip (1) off the branch was never seated). Page 14493 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 16385 GM Engineering is seeing an increase in HVAC control head and actuator warranty where the component is fully functional when received. The root cause of the failure is intermittent wiring connections at the right hand BEC. Specifically, poor terminal tension of the 5V reference or Low Reference terminals in the X4 connector. Refer to the table. After the fault is removed. the actuators recover once commanded. Correction DO NOT REPLACE THE CONTROL HEAD. Use the following information to diagnose this condition: Page 16650 For vehicles repaired under warranty, use the table. Disclaimer Page 21802 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 9091 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components Refer to SIR Identification Views. There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. Page 13409 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 19412 For vehicles repaired under warranty use, the table. Disclaimer Page 5352 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6624 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 2386 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Electrical - Various Electrical Malfunction/Systems Inop Wiper Motor: All Technical Service Bulletins Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 11991 4. Reposition the knock sensor sleeve (2) down, away from the knock sensor. 5. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. 6. Remove the knock sensor bolt and sensor. Installation Procedure Page 5779 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 14115 7. Before disconnecting the 16-way connector, inspect for any backed out terminals (2) as shown. Fully seated terminals (1) are shown for comparison. 1. If a backed out terminal (2) is found, identify the terminal(s) on the repair order. 2. Look at the connector in order to identify the number of the cavity with the backed out terminal. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List in SI. 8. Use the following procedure to disconnect the 16-way electrical connector: 1. For 2ML70 Only: Disconnect the 24-way electrical connector. 2. Release and hold the slide lock on the wiring harness connector. 3. Rotate the connector lever and remove the connector from the component. 9. Repair or replace the terminal(s) as necessary using the following procedure: Specifications Spark Plug: Specifications Spark Plug Gap.................................................................................................................................... ...........................................................1.5 mm (0.06 in) Spark Plug Torque......................................... ................................................................................................................................................15 N.m (11 lb ft) Page 9569 Page 2723 Page 888 Body Control Module (BCM) X6 Page 10798 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 4109 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 9354 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 24202 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 8273 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 4148 Fuse Block - Underhood X2 Page 6518 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12095 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 10205 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 23318 Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE MONITOR SYSTEM The Tire Pressure Monitor System (TPMS) uses radio and sensor technology to check tire pressure levels. If your vehicle has this feature, sensors are mounted on each tire and wheel assembly, except the spare tire. The TPMS sensors monitor the air pressure in your vehicle's tires and transmit tire pressure readings to a receiver located in the vehicle. The TPMS is designed to alert the driver, if a low tire pressure condition exists. If your vehicle has the Driver Information Center (DIC), the driver may also check tire pressure levels using the DIC. When a low tire pressure condition is detected, the TPMS will illuminate the low tire pressure warning symbol located on the instrument panel cluster. If your vehicle has the DIC feature, a message to check the pressure in a specific tire will also appear on the DIC display. The low tire pressure warning symbol on the instrument panel cluster and the "CHECK TIRE PRESSURE" warning message on the DIC display will appear at each ignition cycle until the tires are inflated to the correct inflation pressure. You may notice, during cooler weather conditions, that the tire pressure monitor light, located on the instrument panel cluster, and the "CHECK TIRE PRESSURE" message will appear when the vehicle is first started and then turn off as you start to drive the vehicle. This could be an early indicator that the tire pressures are getting low and need to be inflated to the proper pressure. Each tire, including the spare (if provided), should be checked monthly when cold and inflated to the inflation pressure recommended by the vehicle manufacturer on the vehicle placard or tire inflation pressure label. (If your vehicle has tires of a different size than the size indicated on the vehicle placard or tire inflation pressure label, you should determine the proper tire inflation pressure for those tires.) As an added safety feature, your vehicle has been equipped with a tire pressure monitoring system (TPMS) that illuminates a low tire pressure telltale when one or more of your tires is significantly under-inflated. Accordingly, when the low tire pressure telltale illuminates, you should stop and check your tires as soon as possible, and inflate them to the proper pressure. Driving on a significantly under-inflated tire causes the tire to overheat and can lead to tire failure. Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle's handling and stopping ability. Please note that the TPMS is not a substitute for proper tire maintenance, and it is the driver's responsibility to maintain correct tire pressure, even if under-inflation has not reached the level to trigger illumination of the TPMS low tire pressure telltale. Your vehicle has also been equipped with a TPMS malfunction indicator to indicate when the system is not operating properly. The TPMS malfunction indicator is combined with the low tire pressure telltale. When the system detects a malfunction, the telltale will flash for approximately one minute and then remain continuously illuminated. This sequence will continue upon subsequent vehicle start-ups as long as the malfunction exists. When the malfunction indicator is illuminated, the system may not be able to detect or signal low tire pressure as intended. TPMS malfunctions may occur for a variety of reasons, including the installation of replacement or alternate tires or wheels on the vehicle that prevent the TPMS from functioning properly. Always check the TPMS malfunction telltale after replacing one or more tires or wheels on your vehicle to ensure that the replacement or alternate tires and wheels allow the TPMS to continue to function properly. The "CHECK TIRE PRESSURE" warning message and low tire pressure light (telltale) will come on each time the vehicle is started until the tires are inflated to the correct inflation pressure. The Tire and Loading Information label (tire information placard) shows the size of your vehicle's original tires and the correct inflation pressure for your vehicle's tires when they are cold. Your vehicle's TPMS can alert you about a low tire pressure condition but it does not replace normal tire maintenance. NOTICE: Do not use a tire sealant if your vehicle has Tire Pressure Monitors. The liquid sealant can damage the tire pressure monitor sensors. Page 16420 X276 Inline Harness Connector End Views X276 Steering Column Harness to Inflatable Restraint Steering Wheel Module Coil (KA9) Page 22479 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 7958 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 5115 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 3773 Fluid - A/T: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement Page 12619 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 2248 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 15319 Page 22320 Seat Cushion: Service and Repair Front Seat Center Cushion Replacement Front Seat Center Cushion Replacement Page 7672 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 17867 Page 7626 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 17012 Page 9352 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 6643 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 1984 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 23532 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) X3 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) X4 Page 8616 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Body - Tonneau Cover Fits To Loose On Vehicle Truck Bed Cover Latch: All Technical Service Bulletins Body - Tonneau Cover Fits To Loose On Vehicle TECHNICAL Bulletin No.: 09-08-66-003A Date: December 23, 2010 Subject: One-Piece Hard Tonneau Cover Fits Loose on Vehicle or Rear Tonneau Latch Not Functioning Properly (Adjust Rear Latch and Align Tonneau Cover) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-003 (Section 08 - Body and Accessories). Condition Some customers may comment that the hard tonneau rear latch is not functioning properly or that the tonneau cover is loose on the vehicle, causing noticeable movement during vehicle operation. Cause This condition may be caused by both sides of the latch not engaging or releasing at the same time, or the tonneau frame may be misaligned. Correction Note The tonneau cover latches contain multiple design features to accommodate for build variation of the pickup box and tonneau cover. Use the following repair process to obtain proper latch operation: Inspect/Adjust Latch to Striker Loop Interface Side to Side Adjustment 1. Lower the endgate. 2. Slowly lower the tonneau cover from the open to closed position. Use caution not to drop or slam the tonneau cover closed as this may damage the latch assembly. 3. Inspect the fit of the latch into the striker loop just before the U-shaped catch is engaged. The latch should fit into the striker loop without contacting any portion of the rear bracket or striker loop. If contact is observed, proceed with the following steps: 1. Loosen the two nuts of the rotary latch that is making contact to the striker loop assembly with a 7/16 inch wrench. 2. Slide the rotary latch side to side until the latch freely falls into the rear striker loop. 3. Tighten the rotary latch nuts to 2.26 Nm (20 lb in). 4. Inspect the operation of the latches by turning the twist handle. If the latches do not close or release properly, adjust the latch wire per the Inspect/Adjust Latch Release Operation section of this document. Up and Down Adjustment 1. Lower the endgate. 2. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 3. Inspect the fit of the tonneau cover side seal to the pickup box. If the seal does not have complete contact, lower the striker loop until the seal has complete contact using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Lower the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). 4. Inspect for seal contact and repeat procedure as necessary. 4. Close the endgate. 5. Close the tonneau cover by pushing down on the panel near the twist handle on the top of the tonneau cover. 6. Inspect that both latches have engaged by lifting up on the corner of the tonneau. Page 13132 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 4102 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 4119 Part 1 Electrical Center Identification Views Junction Block - Left I/P, Top View Page 4530 Notice: Completely engage the J 38606 jaws on the valve spring. The J 38606 may slip off and scratch the valve spring. Replace the valve spring if the valve spring becomes scratch. 8. Use J 38606 when J 5892-D will not fit. 9. Remove the valve keys (1). 10. Carefully release the valve spring tension. 11. Remove the J 5892-D or the J 38606. 12. Remove the valve spring cap (2) and valve spring (3). 13. Remove the valve stem oil seal (4). Installation Procedure Important: The exhaust valve oil stem seal has the letters EX (1) molded into the top of the seal. The exhaust valve oil stem seal material is brown in color (2) with a white stripe (3) painted onto the outside diameter of the seal, or the material may be red in color (2) with no paint stripe. The intake valve oil seal is black in color. 1. Assemble the valve into the proper valve guide. 2. Select the proper valve stem oil seal for the specific valve guide. 3. Lubricate the valve stem oil seal and the outside diameter of the valve guide with clean engine oil. 4. Assemble the valve stem oil seal onto the valve stem. Page 5710 Body Control Module: Diagrams Data Communication Connector End Views Body Control Module (BCM) X1 Page 17060 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 15708 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.3L) Removal Procedure 1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... ............................................. 16.5 quarts (15.6 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 2856 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 15002 Transmission Control Module (TCM) 80-Way Connector (Part 1) Page 16972 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 1071 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 19335 Central Control Module: Diagrams Entertainment/Communication Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Locations Intake Air Temperature Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 2468 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 5770 Page 18142 5. Clean and mask and paint the wheels. General Refinishing Procedures - Installation 1. Unmask the wheels. 2. Clean all wheel mounting surface of any corrosion, overspray, or dirt. Important: When re-balancing a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. 3. Install NEW coated balance weights at marked locations. Important: Use a torque stick on an impact wrench, or a torque wrench to consistently and uniformly fasten the wheel to the specified torque for the vehicle. The star pattern must be followed. 4. Install wheels on vehicle. Repair Option Number 2 - Outside Companies * Some outside companies are offering wheel refinishing services. One such company, Transwheel Corporation (800-892-3733), provides this service with GM guidelines. Other companies may also exist. * Any process that re-machines or otherwise remanufactures the wheel should not be used. * The wheel ID must be recorded and follow the wheel throughout the process to assure that the same wheel is returned. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is longer. * Paint and/or clearcoat must not be present on the following surfaces, the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. * A refinishers responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Electrical - Various Rear Door Electrical Malfunctions Fuse: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Capacities Page 11248 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 6756 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 6177 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 5518 8. Install the catalytic converter to muffler nuts. Tighten the nuts to 45 N.m (33 lb ft). 9. For vehicles equipped with 4WD perform the following steps, for vehicles equipped with 2WD proceed to step 13. 10. Connect the engine wiring harness electrical connector (6) to the left front HO2S electrical connector (7). 11. Install the CPA retainer. 12. Install the HO2S electrical connector clip to the fuel line clip (2). Page 4046 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 10524 Fuel Pressure: Service Precautions Relieving Fuel Pressure Caution Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 12350 Notice: Refer to Fastener Notice. 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 N.m (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 24206 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12939 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 22596 Passenger Door Switch (PDS) X7 (AN3/DL3) Page 6653 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 5075 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 2970 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 6554 4. Position the knock sensor heat shield to the engine block and install the bolt. Tighten the bolt to 10 N.m (89 lb in). 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. Page 4655 in) at any of the oil pan-to-transmission housing measurement points (1), then repeat the step until the oil pan-to-transmission housing clearance is within specifications. The oil pan must always be forward of the rear face of the engine block. Notice: Refer to Fastener Notice. 8. Tighten the oil pan bolts and nuts in the sequence shown. Tighten the bolts to 25 N.m (18 lb ft). 9. Measure the clearance at the oil pan-to-transmission housing measurement points in order to ensure proper alignment. 10. Install a NEW drain plug O-ring seal onto the drain plug. 11. Install the drain plug. Tighten the plug to 25 N.m (18 lb ft). Interior - Excessive Wind Noise In Interior Of Vehicle Sound Proofing / Insulation: Customer Interest Interior - Excessive Wind Noise In Interior Of Vehicle TECHNICAL Bulletin No.: 10-08-58-001E Date: March 08, 2011 Subject: Excessive Wind Noise Coming from Rear Interior of Vehicle (Perform Repair as Outlined) Models: 2007-2011 Chevrolet Silverado Crew Cab and Extended Cab 2007-2011 GMC Sierra Crew Cab and Extended Cab Supercede: This bulletin is being revised to update the repair in the Customer Enthusiasm section and update the Parts Information. Please discard Corporate Bulletin Number 10-08-58-001D (Section 08 - Body and Accessories). Condition Some customers may comment on hearing excessive wind noise coming from the rear interior of the vehicle. Cause #1 This condition may be caused by a void in the body filler within the C-pillar. Cause #2 This condition may be caused by the body rear panel acoustic insulator that is mounted behind the rear seat. There is an access flap (1) in this panel that could cause excessive noise if the flap is not fully seated/closed into the rest of the insulator material. Also, starting in 2010, a new insulator was installed that may allow higher wind/road or other acoustic noise that may be objectionable for some customers. Noise penetration into the cab can be higher than a similarly equipped 2009, or earlier, model. As shown in the graphic above, note that the service part insulator (1) is noticeably thicker than the original 2010 part (2). Correction #1 Note This repair is specific to 2007-2010 model years. Page 24176 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 10046 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Engine Splash Shield Replacement - Left Side Splash Guard: Service and Repair Engine Splash Shield Replacement - Left Side Engine Splash Shield Replacement - Left Side Page 20049 Speaker: Service and Repair Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Page 15228 7. If one of the pistons fails to be removed from the brake caliper, perform the following steps. 1. Reposition the piston that has been removed back into the brake caliper. 2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated. 3. Position a second block of wood in front of the piston that remains in the brake caliper. 4. Cover the brake caliper with a shop towel. 5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. 8. Remove the pistons (3) from the caliper bores. 9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores. 10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool. 11. Remove the bleeder valve cap (5). 12. Remove the bleeder valve (6) from the caliper housing (1). 13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air. 14. Replace the pistons or the caliper if any of the following conditions exist: Page 14097 16. Lower the vehicle. 17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 18. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Inspection of Fuse Block Inspection of Fuse Block - I/P (Left Side) for Loose Connector X1 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Disconnect Caution and Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side fuse block as shown. 4. Inspect connector X1 (1) on the back of the fuse block for a loose connection as shown. Secure the connector as needed. 5. Install the left side fuse block. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness Near Park Brake Pedal Assembly Chafed IP Wiring Harness Near Park Brake Pedal Assembly The above condition may cause one or more of the following fuses to open: - 60A - MBEC1 (#72) (Underhood) - 30A - AMP (#40) (Underhood) - 15A - RDO (#41) (Underhood) - 10A - IPC (#46) (Underhood) - 15A - AIRBAG BATT (#51) (Underhood) - 10A - DSM (Left side of IP) Five Areas of Potential Contact Have Been Identified Five areas of potential contact have been identified: Page 16098 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 5494 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor from the cylinder head. Installation Procedure Notice: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, Page 2290 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 11085 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 6486 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 4933 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 8249 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 18672 Sensor Replacement Guidelines The SIR/side air bag sensor replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. An example of this would be a moderate collision where the front of the vehicle impacts a tree, if the vehicle has an SIR sensor mounted forward of the radiator, replace the SIR sensor. * Replace the sensor whether or not the air bags have deployed. * Replace the sensor even if the sensor appears to be undamaged. Sensor damage which is not visible, such as slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the SIR/side air bag sensing system. Do not try to determine whether the sensor is undamaged. Replace the sensor. Also, if you follow a diagnostic trouble code (DTC) table and a malfunctioning sensor is indicated, replace the sensor. Page 3954 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 7066 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 17036 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 5147 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 9074 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13165 7. Remove the plugs from the transmission oil cooler line fittings. 8. Connect the transmission oil cooler lines. 9. Remove the transmission heat shield. Tighten the bolts to 17 N.m (12 lb ft). 10. Tighten the right exhaust pipe nuts. Tighten the nuts to 50 N.m (37 lb ft). Page 2301 Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (2) up and over the knock sensor. Page 22119 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Page 15475 5. Connect the right rear park brake cable (1) to the intermediate cable equalizer bar (2). 6. Insert the park brake cable conduit (3) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 7. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling. 8. Adjust the park brake. Refer to Park Brake Adjustment (Disc Brake) Park Brake Adjustment (Drum Brake). Parking Brake Rear Cable Replacement - Right Side (JF3, JF7) Parking Brake Rear Cable Replacement - Right Side (JF3, JF7) Tools Required j 37043 Park Brake Cable Release Tool Removal Procedure Page 7419 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 2031 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 11222 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 1332 Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Page 22318 Seat Cushion: Service and Repair Front Center Seat Cushion Cover and Pad Replacement (AE7) Front Center Seat Cushion Cover and Pad Replacement (AE7) Page 15910 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 17003 Page 16467 X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, replace the IPC. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Refer to Programming and Relearning for Control Module setup and programming. See: Testing and Inspection/Programming and Relearning * Instrument Cluster Replacement (without RPO SLT) Instrument Cluster Replacement (with RPO SLT) Page 8168 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 10918 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 18210 Air Temperature Actuator Replacement - Left Side Air Temperature Actuator Replacement - Left Side Page 8060 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 16787 Auxiliary Power Outlet: Connector Views Power Outlet Connector End Views Auxiliary Power Outlet - Bin (D07) Auxiliary Power Outlet - Center Seat (AZ3) Auxiliary Power Outlet - Console (D07) Specifications Spark Plug: Specifications Spark Plug Gap.................................................................................................................................... ...........................................................1.5 mm (0.06 in) Spark Plug Torque......................................... ................................................................................................................................................15 N.m (11 lb ft) Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 6737 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 14683 Pressure Regulating Solenoid: Service and Repair Control and Shift Solenoids Replacement Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 16275 Junction Block - Left I/P X8 Page 12223 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 3472 Alignment: Specifications Trim Height Specifications Trim Height Specifications Trim Height Specifications Page 8219 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 4768 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Circuit/System Verification Important: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. Ignition ON, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. ‹› If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 1. Ignition OFF, all accessories OFF, install the CH-48027. Refer to Fuel Pressure Gage Installation and Removal. See: Fuel Pressure Gage Installation and Removal 2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Important: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Restricted or plugged fuel filter * Restricted or plugged strainer * Stuck or binding fuel level float * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel Page 6783 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 23085 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 13118 Clutch Control Solenoid Valve: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 3. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) Page 7915 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 3565 1. Ensure that the spark plug washer is positioned correctly. 2. Inspect the spark plug gap. Adjust the gap as needed. 3. Install the spark plug into the cylinder head by hand. (left side shown, right similar). Notice: Refer to Fastener Notice. 4. Tighten the spark plug. Tighten the plug to 15 N.m (11 lb ft). 5. If reinstalling the old spark plug wires, apply dielectric grease GM PN 12345579 (Canadian PN 10953481), or equivalent to the inside the spark plug wire boots. 6. Install the appropriate spark plug wire boot(s) (2) to the spark plug. (left side shown, right similar). Page 18559 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4918 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 8301 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 16891 Page 21041 Tighten bolt to 11 N.m (97 lb in). 6. Install the rear sliding window lower garnish molding. 7. Inspect the rear sliding window for proper operation. Page 2105 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 1809 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 9448 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 5601 Tighten the right exhaust manifold pipe bolts in the sequence indicated in illustration "B" above. Tighten: Tighten the bolts to 50 N.m (37 lb ft). Tighten the Y-pipe outlet to the exhaust muffler assembly. Tighten: Tighten to 45 N.m (33 lb ft). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 18065 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 9356 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 4073 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 23552 Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: Customer Interest Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6755 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 22503 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 14277 5. Slide the boot (5) down the halfshaft bar (4) and away from the CV joint outer race (1). 6. Wipe all grease away from the face of the CV joint. 7. Find the halfshaft bar retaining snap ring (3), which is located in the inner race (2). 8. Spread the snap ring ears apart using J 8059 (or equivalent). 9. Pull the CV joint (1) and the CV joint boot (5) from the halfshaft bar (4). 10. Discard the old CV joint boot (5). Page 10428 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 9782 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 13905 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. Tighten the nut or nuts to 40 N.m (30 lb ft). 5. Remove the transmission jack. 6. Lower the vehicle. Page 16417 X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) Page 10262 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 16145 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Mobile Radio Blunt Cuts 11 - X226 12 - Instrument Panel G108, G110, G111, and G104 Page 4032 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12716 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 14897 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 9690 Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (3). Tighten the sensor to 42 N.m (31 lb ft). 3. Install the HO2S pigtail electrical connector clip to the engine wiring harness clip (3). Page 11925 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 11420 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 12546 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 13808 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 2048 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 1786 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 18278 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 21719 Memory Seat Module X6 (AN3) Page 20083 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 8132 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 14349 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Page 9914 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2808 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 24224 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Allison - Automatic Transmission Pressure Regulating Solenoid: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Mod Main Pressure Control Solenoid Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Page 17308 Entertainment System - Rear DVD Screen Inoperative/Blank DVD Player: Customer Interest Entertainment System - Rear DVD Screen Inoperative/Blank TECHNICAL Bulletin No.: 06-08-44-032B Date: April 10, 2008 Subject: Rear (2nd and *3rd Row (*where applicable)) DVD Screen Blank/Inoperative, Speaker Pop Noise, Battery Draw, OnStar(R) Audio Inoperative, Nav Screen Flashing, Radio Display Flashing (Inspect and Repair Wiring Harness if Necessary) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT* 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe* 2007-2008 Chevrolet Equinox 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL* 2007-2008 Pontiac Torrent with Rear Seat Entertainment System (RPOs U42, UUC) Supercede: This bulletin is being revised to add RPO UUC. Please discard Corporate Bulletin Number 06-08-44-032A (Section 08 - Body and Accessories). Condition Some customers may comment on any one of the following concerns: ^ Rear DVD Screen Inoperative. ^ Pop Noise in all speakers when cranking the engine. ^ Battery Draw or Battery goes dead. ^ OnStar(R) Inoperative. ^ No Sound from speakers. ^ No OnStar(R) Audio. ^ Navigation screen "Flashing on and off". ^ Radio display "Flashing on and off". Cause This condition may be due to an open or shorted wiring harness near the rear DVD display screen under the headliner. Correction To properly inspect for this condition perform the following steps: 1. Lower the rear DVD screen. 2. Remove the four retaining screws that hold the DVD to the headliner. In order to remove the screen assembly from the overhead bezel a firm tug should be applied to unseat the Z-axis clip. Page 2063 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 10316 Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Training (Canada) To access the training video on AFIT, take the following path at the GMPro LMS Training Website: 1. After logging into the website, choose the link on the left side of the page titled "Catalog." 2. Then choose "Catalog Search." 3. Next, within the search box, Select Course Number - Contains - "T" then select search. 4. This will bring up a list of TECHassist courses. Scroll through to choose "Active Fuel Injector Tester" and select "View." 5. At this point, a new window will open and the program can be Launched. Also, dealers can now download software updates for the AFIT at GM Dealer Equipment (GMDE). Techlink Additional information can be found on AFIT (June 2006 Edition) and GM Upper Engine and Fuel Injector Cleaner (November 2006 Edition) in Techlink. To access the articles, take the following path: 1. Go to GM DealerWorld (U.S.) or the GM GlobalConnect (Canada). 2. Click on the Service Tab in DealerWorld (in Canada, click Technican Resources in the Service Library of GM GlobalConnect). 3. Click on the GM Techlink Hyperlink. 4. Click on the Archives Hyperlink at GM Techlink. - Click on 06-2006 in the Archives Section and Click on the Active Fuel Injector Tester Link in the June 2006 Techlink Article. - Click on 11-2006 in the Archives Section and Click on the GM Top Engine Cleaner Replaced Link in the November 2006 Techlink Article. Injector Cleaning Procedure Notice GM UPPER ENGINE AND FUEL INJECTOR CLEANER is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank. Do not exceed the recommended cleaning solution concentration. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure. Important Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have any out of specification injectors replaced. 1. For 4, 5 and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A - Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) mixed with 420 ml (14 oz) of regular unleaded gasoline. 2. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner container into the J 35800-A Injector Cleaning Tank then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for a second time for an 8 cylinder engine (8 cylinder engines receive 960 ml total fluid 120 ml (4 oz) of Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline. 3. Be sure to follow all additional instructions provided with the tool. 4. Electrically disable the vehicle fuel pump by either removing the fuel pump fuse or the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. Page 13919 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Notice: Refer to Fastener Notice. 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 N.m (92 lb in). 5. Install the control valve assembly. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 20637 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverage Adjustments are displayed in the Applicable Warranties section. Parts Information Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Replace door handle levers if signs of peeling are present. Note The handle kit contains two door handle levers, replace both sides. Front Side Door Inside Handle Replacement 1. Remove the driver and passenger front side door inside handles. Refer to Front Side Door Inside Handle Replacement in SI. 2. Place front door inside handles on a work bench. Page 5025 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 10698 4. Inspect for fuel leaks. Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 2462 Page 385 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 24209 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 10240 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 11527 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 1727 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 8264 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 6140 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Page 7370 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 1895 Page 4251 Notice: Refer to Fastener Notice. Important: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3). Tighten the TORX screw to 1.3 N.m (11.5 lb in). Important: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 1. Apply tire soap to the rubber portion of the valve stem (1). 2. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 11001 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 22971 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9340 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 1034 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 12892 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 12945 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 2552 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 14401 1. Install the front propeller shaft by sliding the front propeller shaft into the transmission or the transfer case, w/o RPO MW7. 2. Install the front propeller shaft to the transmission pinion yoke, w/RPO MW7. Important: * Align the reference marks made during removal. * Tighten the bolts until snug. Do not torque the bolts at this time. Install the yoke retainers and the bolts, w/RPO MW7. 3. Install the center bearing support (2). Notice: Refer to Fastener Notice. 4. Install the center bearing support nuts. Tighten the bearing support nuts to 40 N.m (30 lb ft). 5. Tighten the yoke retainer bolts, w/ RPO MW7. Tighten the yoke retainer bolts to 25 N.m (18 lb ft). 6. Inspect the splines of the front propeller shaft stub shaft for a sufficient coating of grease. If the splines of the stub shaft does not have a sufficient coating of grease, lubricate the shaft with chassis grease, GM P/N 12377985 or equivalent. Page 144 Parking Assist Control Module: Service and Repair Object Alarm Module Replacement Page 4894 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 13142 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 1982 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Instruments - Hard to See/Poor Backlighting Instrument Panel Control Module: Customer Interest Instruments - Hard to See/Poor Backlighting Bulletin No.: 07-08-49-029A Date: January 25, 2008 TECHNICAL Subject: Instrument Panel (IP) Gauges/Gages Difficult to Read or See Poor Backlighting (Replace IP and Program) Models: 2007 Chevrolet Avalanche Silverado Suburban Tahoe 2007 GMC Sierra Sierra Denali Yukon Yukon Denali Yukon XL Yukon Denali XL Supercede: This bulletin is being revised to reflect the latest Utility software part number. Please discard Corporate Bulletin Number 07-08-49-029 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) gauges are difficult to read due to poor backlighting. This condition does not affect the IP cluster operation. Correction DO NOT program the service software into existing 2007 clusters. The service software is designed to work only with the 2008 cluster hardware, which includes a new microprocessor. For IP clusters replaced/programmed due to a customer concern of poor backlighting, warranty claims must be submitted using the labor operation listed in this bulletin. Refer to the Warranty Section for more information. Program the replacement IPC using TIS2WEB Pass-Thru Programming. Select "I/PC" from the Supported Controllers table in TIS2WEB to complete the programming. DO NOT select I/PC Set-up. Mileage and/or Engine Hours must be set by the ESC's prior to installing the IP in the vehicle. DENALI CUSTOMER'S ONLY - Please advise the customer that 2008 Denali clusters are not available. In order to correct this condition, a 2008 Yukon or Sierra cluster will have to be installed in the vehicle. The customer must advise the dealer whether they wish to keep the current 2007 Denali cluster or replace it with a 2008 Yukon or Sierra cluster (which will correct the condition). Programming a 2007 cluster with the 2008 service software can drain the battery and potentially cause a "no start" condition. If the customer is dissatisfied with the IP cluster visibility the current (2007) cluster should be replaced with the 2008 hardware/software. Refer to the charts listed in the Parts Information section of this bulletin to determine the new IP cluster and software part numbers. Page 7183 Camshaft Position Sensor: Connector Views Engine Controls Connector End Views Camshaft Position (CMP) Sensor Page 23135 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 555 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 9494 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 17022 Fuse Block: Locations HVAC - Automatic HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor Page 452 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 16423 Page 17117 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 21736 For vehicles repaired under warranty, use the table. Disclaimer Page 9811 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). OnStar(R) - Language Change Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Page 22042 2. Push the finishing lace (2) onto the track assembly flange (1) until fully seated around the sunroof opening. 3. Pull the finishing lace draw cord toward the sunroof opening. Remove the cord from the periphery of the opening. 4. Ensure that the finishing lace (2) is properly seated over the outer surface of the headliner (3). Page 10828 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 15681 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Page 18661 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Specifications Console: Specifications Fastener Tightening Specifications Page 828 Disclaimer Page 7204 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 19725 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Locations Windshield Washer Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 10701 1. Install the following NEW components to the fuel meter body: * Lower fuel seal (4) * Spacer ring (3) * Upper fuel seal (2) * Fuel seal retainer (1) Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 2. Apply a few drops of clean engine oil to the fuel pipe end. 3. Install the fuel pipe to the fuel meter body. 4. Install the fuel pipe retainer. Page 3955 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 11806 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 9604 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 19388 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 22469 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 8907 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 1501 Seat Lumbar Switch - Driver (AN3) Seat Lumbar Switch - Passenger (AN3) Page 11324 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 6889 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 10422 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 16676 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 473 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1021 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5283 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 10380 Vehicle Zoning Strategy Truck Zoning Page 8719 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 15947 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 6732 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 23740 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 21209 Skid Plate: Service and Repair Engine Shield Replacement Engine Shield Replacement Page 2602 Page 24716 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 3297 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Page 21663 Keyless Entry Receiver: Service and Repair Remote Control Door Lock Receiver Replacement Page 9989 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 10718 Tighten the clamp to 2.5 N.m (22 lb in). 6. Position the fuel tank fill pipe ground wire (1) and the fuel tank fill pipe ground wire (2) to the frame bracket. 7. Install the fuel tank fill pipe ground wire (2) anti-rotation tab into the frame hole. 8. Install the fuel tank fill pipe ground wire bolt (3). Tighten the bolt to 9 N.m (80 lb in). 9. Lower the vehicle. 10. Install the fuel tank filler housing. 11. Install the fuel tank filler housing to fuel tank fill pipe bolts. Tighten the bolts to 2.3 N.m (20 lb in). 12. Install the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). Tighten the screws to 2.3 N.m (20 lb in). Page 24655 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 17222 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 12602 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. A/C - Control Module A/C Indicator Blinking Control Module HVAC: All Technical Service Bulletins A/C - Control Module A/C Indicator Blinking Bulletin No.: 07-01-38-006 Date: August 20, 2007 INFORMATION Subject: Information For Vehicles with HVAC Control Module A/C Indicator Blinking Due to Low Battery State of Charge Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Manual Temperature Control HVAC System (RPO CJ3) An Air Condition (A/C) button on the Heating, Ventilation and Air Conditioning (HVAC) control module may blink when the A/C system is activated. The blinking indicator will turn to a solid light after cycling the A/C button or ignition key. This condition may be caused by a low battery state of charge on a PREVIOUS ignition key cycle. This condition may be due to situations were an unsold vehicle is parked for long periods of time as part of a dealership's unsold inventory. The A/C indicator begins to flash if the battery voltage falls below 9.5 volts. The low voltage condition may occur during an engine crank or if the vehicle is parked and a normal battery state of charge is not maintained. If the A/C indicator continues to blink, use the Tech 2(R) to help determine the cause. Connect the Tech 2 and build the vehicle. Select Powertrain. Select Engine Control Module (ECM). Select Data Display. Select Cooling/HVAC data. Make sure that there has been an A/C request signal. History should indicate any causes. If necessary, refer to SI for further information on HVAC system diagnostic procedures. Page 16618 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 3314 Notice: Refer to Fastener Notice. 3. Install the sensor nut and position the sensor body parallel to the inside wheel surface while torquing. Tighten the sensor nut to 7 N.m (62 lb in). Important: Before reinstalling the tire on the wheel, note the following items to avoid tire pressure sensor damage upon tire mounting: * Position the mounting/dismounting head 180 degrees from the valve stem. * Position the bead transition area 45 degrees counterclockwise of the valve stem. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. * Repeat items for outer bead. Install the tire on the wheel. Important: A service replacement tire pressure sensor is shipped in OFF mode. In this mode the sensor unique identification code cannot be learned into the remote control door lock receiver (RCDLR) memory. The sensor must be taken out of OFF mode by spinning the tire/wheel assembly above 32 km/h (20 mph) in order to close the sensors internal roll switch for at least 10 seconds. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 14755 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. 4L60-E/4L65-E/4L70-E - Automatic Transmission Clutch Control Solenoid Valve: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 15431 Page 11337 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 14670 4. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Tighten the bolt to 11 N.m (97 lb in). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), Page 22764 7. Repeat steps 5 and 6 five more times to look for repeatability. If either one of the sides does not engage, manually close the latch that did not engage and inspect the latch closure of each side by wiggling each corner. Check for the following: 1. If one side is too loose and exhibiting excessive movement, lower the corresponding loop per steps 3.1-3.4 in the Up and Down Adjustment section above. 2. If one side requires excess manual efforts to close, raise the corresponding loop using the following steps: 1. Loosen the two 1/4 inch nuts that hold the striker plate to the rear bracket. 2. Raise the striker loop. 3. Tighten the 1/4 inch nuts to 13.5 Nm (120 lb in). Inspect/Adjust Latch Release Operation 1. Open the tonneau cover. 2. Manually push the U-shaped catches closed for both sides of the vehicle. If either one of the catches does not close, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Push the cable inboard from the end of cable to add length to the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should engage at the same time. 4. Inspect the timing of the latch engagement by manually closing the latches and twisting the lock handle with the cover in the open position. If the latches do not engage at the same time, repeat the above adjustment until they do. 3. Twist the handle and listen for the latches to release. If either one of the catches does not open, proceed with the following steps: 1. Loosen the set screw of the cable bushing with a 5/64 inch allen wrench. 2. Pull the cable outboard from the end of the cable to shorten the length of the cable between the latch assembly and the lock assembly. 3. Retighten the set screw. Note Both latches should release at the same time. 4. Inspect the timing of latch release. Repeat steps 3.1-3.3 above, adjusting the latch that releases second, until both latches are releasing at the same time. Verify that the front frame is centered and squared onto the pickup box 1. Measure from the edge of the front panel sheet metal cross-car to the edge of the hinge clip on both sides. Loosen hardware and adjust the frame position side to side until it's centered. 2. Measure from the stack pocket to the end of the side frame on both sides. Loosen hardware and adjust the frame position until both sides match. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 23117 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5437 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 8141 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 16405 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) to Headliner Harness (UE1/U3U/UVB) Page 4084 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 12935 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 7920 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11558 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 1920 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 13572 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 10979 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 16798 Branching Point: Diagrams JX300 - JX399 Splice Pack Connector End Views JX339 Page 3466 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 15476 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the right park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the right park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). 8. Remove the park brake cable from the cable guides. 9. Remove the brake shoes. 10. Using the J 37043 (1), remove the park brake cable from the backing plate. Page 5772 Vehicle Zoning Strategy Truck Zoning Page 3724 Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Place drain pans under the vehicle as needed. Body - Outside Door Handle(s) Squeak When Operated Rear Door Exterior Handle: Customer Interest Body - Outside Door Handle(s) Squeak When Operated TECHNICAL Bulletin No.: 08-08-64-007 Date: May 13, 2008 Subject: Squeaky Outside Door Handle (Grease U-Channel of Handle) Models: 2007-2008 Cadillac Escalade, Escalade EXT, Escalade ESV 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Condition Some customers may comment on a squeak noise coming from the door handle as the handle is actuated. Cause This condition may be caused by the pin and the inside of pawl surface making contact with each other, resulting in a squeak noise. Correction DO NOT REPLACE THE DOOR HANDLE. 1. Remove the fasteners to the door handle, leaving the rod to the latch attached. 2. Apply a generous amount of dielectric silicone grease, P/N 12345579 (in Canada, 10953481), as shown in the graphics, into the U-channel of the handle between the pawl and the tower where the gray pin enters through the spring and the pawl. 3. Cycle the handle at least 20 times to work the grease around the pin and to make sure that the squeak has been eliminated. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10789 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 14849 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 8898 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 23922 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 1666 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 12126 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 9778 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 11484 Ignition Cable: Service and Repair Spark Plug Wire Replacement Removal Procedure Important: Prior to removing the spark plug wire(s) note the correct routing of the wires as required. 1. Remove the appropriate spark plug wire boot(s) (1, 2) from the ignition coil. 1. Twist the spark plug boot 1/2 turn. 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose, in order to remove the spark plug wire boot from the ignition coil. 2. Remove the appropriate spark plug wire boot(s) (2) from the spark plug. (left side shown, right similar). 1. Twist the spark plug boot 1/2 turn. Page 2790 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 5865 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 12481 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. Page 23262 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 16425 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness Page 6180 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 6572 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 6244 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 9647 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 21304 Tighten the bolts to 22 N.m (16 lb ft). Install the center front seat. Refer to Center Seat Replacement in SI. Install the front seats. Refer to Front Seat Replacement in SI. Install the front seat belts to the seats. Refer to Seat Belt Retractor Pretensioner Replacement in SI. Install the front hinge pillar trim panels. Refer to Body Hinge Pillar Trim Panel Replacement in SI. Install the front door sill plates. Refer to Front Door Sill Plate Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8417 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 7217 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21717 Memory Seat Module X4 (AN3) Page 6116 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 10462 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 11054 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 9603 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 11414 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 5365 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 11338 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 14724 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 20281 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Tail/Stop and Turn Signal Lamp - Lower Right 4 - Marker Lamp - Right Rear 5 - Backup Lamp Right Rear 6 - Object Sensor - Right Rear Corner (UD7) 7 - License Lamp - Right 8 - Object Sensor - Right Rear Middle (UD7) 9 - Marker Lamp - Tailgate (R05) 10 - Object Sensor - Left Rear Middle (UD7) 11 - License Lamp - Left 12 - Object Sensor - Left Rear Corner (UD7) 13 - Backup Lamp - Left Rear 14 - Marker Lamp - Left Rear 15 - Tail/Stop and Turn Signal Lamp - Lower Left TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 23113 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 1985 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement Special Tools j 35468 Cover Aligner and Seal Installer Removal Procedure 1. Remove the crankshaft balancer. 2. Inspect the engine front cover seal bore area for damage. 3. Use a suitable seal puller, remove the crankshaft front oil seal. Installation Procedure Page 23073 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 9764 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 10841 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 2608 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 15092 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Notice: Refer to Fastener Notice. 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 N.m (92 lb in). 5. Install the control valve assembly. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure. Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 8539 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 9019 Page 19398 Driver/Vehicle Information Display: Service and Repair Driver Information Display Switch Replacement (with RPO SLT) Driver Information Display Switch Replacement (with RPO SLT) Page 17348 X125 Inline Harness Connector End Views X125 Heated Oxygen Sensor (HO2S) Jumper Harness to Engine Harness (LY6) Page 9282 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 17278 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 21184 Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolt/Stud First Pass ............................................................................................................................................. ..................................................... 15 N.m 11 lb ft Final Pass ............................................................................................................................................ ..................................................... 30 N.m 22 lb ft Page 12368 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 24683 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 8637 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice Heated Oxygen Sensor Resistance Learn Reset Notice Notice: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 7459 Disclaimer Page 7116 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 6707 Page 10231 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 16235 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Specifications Piston Pin: Specifications Pins Pin - Piston Pin Clearance to Connecting Rod Bore - Press Fit ................................................................................ 0.012-0.048 mm 0.0005-0.0019 in Pin - Piston Pin Clearance to Piston Pin Bore - Production ...................................................................................... 0.013-0.023 mm 0.0005-0.0009 in Pin Piston Pin Clearance to Piston Pin Bore - Service ................................................................................................................... 0.025 mm 0.0010 in Pin Piston Pin Diameter ...................................................................................................................................... 23.545-23.548 mm 0.9270-0.9271 in Page 16242 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 9264 Vehicle Zoning Strategy Truck Zoning Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement (Crew Cab) Rear Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the rear door sill plate. Refer to Rear Side Door Sill Plate Replacement (Extended Cab) Rear Side Door Sill Plate Replacement (Crew Cab) . 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. Page 5837 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 23412 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 4261 6. Install the spare tire to the hoist. Notice: Use only hand tools to lower and raise the spare tire hoist assembly. Do not use air tools. The use of air tools at high speeds will damage the spare tire hoist assembly. 7. Rotate the hoist shaft clockwise until the spare tire is in position and the hoist clicks 2 times or it skips twice. You cannot overtighten the cable. 8. Remove the safety stands. 9. Lower the vehicle. 10. Install the spare tire stowage lock cylinder. Page 13426 Fluid Pressure Sensor/Switch: Specifications Allison - Automatic Transmission Pressure Switch Manifold (PSM) Logic Pressure Switch Manifold (PSM) Logic Page 18097 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. HVAC - Automatic Air Door Actuator / Motor: Locations HVAC - Automatic HVAC Component Views HVAC Module 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P C4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Remove the knock sensor heat shield bolt and shield. Page 13399 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-023 Date: 080508 A/T - Fluid Leak From Bell Housing Area TECHNICAL Bulletin No.: 08-07-30-023 Date: May 08, 2008 Subject: 4L60-E/4L65-E/4L70‐E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Replace Torque Converter Hub-to-Oil Pump Seal Assembly) Models: 2007-2008 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe, TrailBlazer 2007-2008 GMC Envoy, Savana, Sierra, Yukon, Yukon XL 2007-2008 HUMMER H2 2007-2008 Saab 9-7X with 4L60-E, 4L65-E or 4L70‐E Automatic Transmission (RPOs M30, M32 or M70) and 4.8L, 5.3L or 6.0L V8 Engine Attention: This bulletin applies to vehicles built prior to December 2007. Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. Cause Investigation of 2007 transmissions has shown wear of the torque converter hub-to-pump seal (243, illustrated in the Oil Pump Disassembled View in SI). Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If the leak is coming from the bell housing replace the torque converter seal. Page 1006 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 8442 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 19252 For vehicles repaired under warranty, use the table above. Disclaimer Page 186 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 12327 Page 3092 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 10624 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 4325 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 3125 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 19126 Page 7807 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 11511 Page 10771 Page 11062 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 5760 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 10104 13. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 N.m (18 lb ft). 14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. 15. Lower the vehicle. 16. Remove the caps from the fuel rail and EVAP line. 17. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line.. 18. Connect the fuel feed line (1) quick connect fitting to the fuel rail. 19. Install the fuel fill cap. 20. Connect the negative battery cable. 21. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Page 17784 5. Remove the steering shaft coupling nut (1) and bolt (2) at the steering column. 6. Remove the upper intermediate steering shaft from inside the engine compartment. Installation Procedure Important: If a new steering shaft coupling is being installed then transfer the position of the alignment marks from the old component to the same locations on the new component. Failure to transfer the alignment marks may result in an off-center steering wheel after installation. 1. Install the upper intermediate steering shaft from inside the engine compartment. Notice: Refer to Fastener Notice. 2. Install the steering shaft coupling nut (1) and bolt (2) at the steering column. Tighten the nut and bolt to 62 N.m (46 lb ft). Page 8178 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Notice: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Important: It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. 3. Disengage the engine wiring harness upper electrical connector retainer (2) and remove the connector (1) from the ECM. 4. Disengage the engine wiring harness lower electrical connector retainer (3) and remove the connector (4) from the ECM. Page 12111 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 7394 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 15019 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 13015 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 7296 Locations Audible Warning Device Control Module: Locations Displays and Gages Component Views Chime Module (UL5) 1 - Chime Module (UL5) Page 2534 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 14934 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 1704 Brake Light Switch: Diagrams Trailer Brake Control Trailer Brake Control Connector End Views Trailer Brake Controller Solid State Relay Trailer Brake Controller Solid State Relay Trailer Brake Control Panel Switch Page 7711 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 13195 12. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: * Clutch material * Bronze slivers indicating bushing wear * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. 4. Install the oil pan and NEW gasket. Page 10901 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 13564 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Specifications Engine Oil Pressure: Specifications Oil Pressure - at 1,000 RPM ................................................................................................................ ............................................................ 42 kPa 6 psi Oil Pressure - at 2,000 RPM .............................. ........................................................................................................................................... 125 kPa 18 psi Oil Pressure - at 4,000 RPM ..................................................................................................... .................................................................... 166 kPa 24 psi Page 13731 Torque Converter: Service and Repair Torque Converter Replacement Tools Required * J 21366 Converter Holding Strap * J 46409 Torque Converter Lifting Handles * J 44723 Transmission/Stand Adaptor Plate Removal Procedure 1. Remove the transmission from the vehicle. 2. Install J 21366 to restrain the torque converter. 3. Install J 44723. Refer to Holding Fixture Installation. 4. Position the transmission vertically with the torque converter end up. 5. Remove J 21366 torque converter retaining bracket. Page 16349 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Locations Heated Glass Element Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Heated Oxygen and Oxygen Sensor Notice Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Notice Heated Oxygen and Oxygen Sensor Notice Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Page 17343 X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness (JL4) Page 16712 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 4086 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6322 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 9873 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 7387 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Input Speed Sensor (ISS) Harness Page 470 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 11157 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 23600 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 21875 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 15732 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 6. Remove the oil pan skid plate and bolts, if equipped. 7. Remove the negative battery cable bolt (2) from the front of the engine block. 8. Reposition the negative battery cable terminal (1) and the engine wiring harness terminal (3) from the engine block. Page 14279 18. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 19. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. 1. The inner and outer race assemblies 2. The CV joint cage 3. The chrome alloy balls 20. Dry all the parts. 21. Check the CV joint assembly for unusual wear, cracks, or other damage. 22. Replace any damaged parts. 23. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Procedure 1. Inspect all of the parts for unusual wear, cracks, or other damage. Replace the CV joint assembly if necessary. 2. Put a light coat of the recommended grease on the inner (6) and the outer race (8) grooves. Page 10078 4. Connect the EVAP vent solenoid pipe quick connect fitting (3) to the EVAP canister. 5. Install the EVAP vent solenoid pipe clip (1) to the frame crossmember. 6. Connect the chassis wiring harness electrical connector to the EVAP canister vent solenoid. 7. Install EVAP canister vent solenoid clip (1) to the chassis EVAP line. 8. Install the EVAP canister vent solenoid pipe to the clip (2) on the chassis EVAP line. 9. Install the EVAP canister vent solenoid pipe to the clips (3) on the brake pipes. 10. Lower the vehicle. Page 9062 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 8002 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 11229 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 2039 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 21436 Instrument Panel Compartment Door Lock Cylinder Replacement Instrument Panel Compartment Door Lock Cylinder Replacement Removal Procedure 1. Remove the instrument panel compartment latch. Refer to Instrument Panel Compartment Door Latch Replacement (without RPO SLT) Instrument Panel Compartment Door Latch Replacement (with RPO SLT) . 2. Position the instrument panel compartment latch fork bolt in the up position. 3. Insert the key into the instrument panel compartment lock cylinder. 4. Rotate the instrument panel compartment lock cylinder clockwise to the 3 o'clock position with the key. 5. With the key in position, apply a light load and depress the retainer tumbler through the poke hole at the right hand side of the instrument panel compartment latch. Page 18937 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Page 12081 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 14727 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2864 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 5388 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 12963 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 14952 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 6390 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 5768 Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Control Module: Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 23209 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 7655 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 3880 Page 8761 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Page 23108 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 4576 5. If equipped without A/C, install the belt (1) to the pulleys and the drive belt tensioner. 6. Slowly release the tension on the belt tensioner (2). 7. Remove the breaker bar from the drive belt tensioner. 8. Inspect the drive belt for proper installation and alignment. Page 16386 The concern must be current before diagnosis can be performed. Review and print the following SI documents - Electrical Center Identification Views, for use during diagnosis: - Junction Block - Right I/P, Top View - Junction Block - Right I/P X4 - Junction Block - Right I/P X5 Locate the Junction Block - Right Side IP on the vehicle. For the appropriate actuator, measure the following signals for voltage/resistance from the BACK of the X4 or X5 connector and record the following: DO NOT unplug the X4/X5 connector. Turn Ignition On, A/C Blower Full, if possible - mode on "panel" and Temp to "cold." Once the fault is removed, the actuator will stay in default position until commanded to a new position. Change commanded position regularly to see if the issue is still current. Continue to monitor door positions (feedback) on Tech2 to see if it changes during circuit testing. - Ignition Voltage - 12V - Door Control Signal - 2.5V when stationary, OV when commanded toward "cold" or "panel", 5V when commanded toward "hot" or "defrost" - Low Reference - less than 40 ohm with ignition on. Less than 10 ohm with ignition off - Door Position Signal - measure voltage - 5 Volt Reference - 5V If any signals do not display the correct value or if the issue is corrected during testing, pull the connector and check the terminal for poor tension (use the appropriate terminal tool). Replace or repair the terminal if poor tension is found. If all signals are correct at RH BEC, reconfirm the customer's comments. If the condition is not present, no further repairs are necessary. If the condition is still present, recheck the actuator connector 5 volt reference circuit, pin drag test and repair connector/pin as necessary. Warranty Information For vehicles repaired under Enqineerinq direction, use the table. Page 11760 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor Assembly, Wiring Harness Side Page 16985 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 16027 Page 15937 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 22942 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Locations Steering Angle Sensor: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 18772 1 - Door Frame 2 - Window Switch - Driver (A31 -AN3/DL3) 3 - Outside Rearview Mirror - Driver 4 Memory/Heated Seat Switch (AN3) 5 - Outside Rearview Mirror Switch (DL8/DPN) 6 - Driver Door Switch (DDS) (AN3/DL3) 7 - Speaker - Left Front 8 - Window Motor - Driver (A31) 9 - Door Lock Switch - Driver (AU3 -AN3/DL3) 10 - Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) 11 - Door Latch Assembly - Driver Passenger Door Page 17124 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 13583 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 9700 Page 13522 Page 8464 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 7848 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 2771 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Page 13938 Transmission Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Turbine Speed Sensor Page 1335 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 9385 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 2714 Page 1107 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 17039 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 9592 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 22447 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 17353 OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 20993 Rear Door Panel: Service and Repair Rear Side Door Water Deflector Replacement Rear Side Door Water Deflector Replacement Page 10490 Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures Fuel Injector Replacement Page 13404 Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 09-07-30-004C Date: 110113 A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Page 12947 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 9488 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 5132 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 8257 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 11937 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13029 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 19710 Page 14064 Ball Check Valve Locations Ball Check Valve Locations Page 15326 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, Page 20197 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Fuel System - Driveability Issues/MIL/Multiple DTC's Fuel Injector: Customer Interest Fuel System - Driveability Issues/MIL/Multiple DTC's TECHNICAL Bulletin No.: 03-06-04-030G Date: April 22, 2009 Subject: Various Driveability Symptoms Due to Clogged Fuel Injectors, MIL/SES DTCs P0171, P0172, P0174, P0300, P1174, P1175 (Clean Fuel Injectors and/or Perform Injector Test With AFIT CH-47976) Models: 2005-2009 GM Passenger Cars and Light Duty Trucks 2005-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Equipped with Engine RPOs listed in the Table above and MULTEC(R) 2 Fuel Injectors Attention: GM does not support cleaning injectors on any engines that are not listed in this bulletin. Engines other than the ones listed in this bulletin that diagnosis indicates having restricted injectors should have those injectors replaced. Supercede: This bulletin is being revised to update the model year to 2009 and to provide applicable engine RPO table. Please discard Corporate Bulletin Number 03-06-04-030F (Section 06 - Engine/Propulsion System). Condition Some customers may comment on any of the following various driveability symptoms: - Extended Crank Time - Hard to Start - MIL/SES Illuminated with DTCs - Hesitation - Lack of Power - Surge or Chuggle - Rough Idle - Light or Intermittent Misfire Cause Due to various factors, the fuel injectors may become restricted. Extensive testing has demonstrated that fuel related issues are the cause of clogged injectors. At this point, no specific fuel, fuel constituent, or engine condition has been identified as causing the restriction. The restriction causes the engine to operate at a lean air fuel ratio. This may either trigger the MIL to illuminate or the engine to develop various driveability symptoms. Correction Page 24228 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 16160 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 14855 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 21994 Sunroof / Moonroof Track: Service and Repair Sunroof Track Timing/Synchronization (Crew Cab) Sunroof Track Timing/Synchronization (Crew Cab) Removal Procedure 1. Place the module in the closed/flush position. 2. Remove the sunroof window. Sunroof Window Replacement (Crew Cab) Sunroof Window Replacement (Extended Cab). 3. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Regular Cab) Headlining Trim Panel Replacement (Extended Cab) Headlining Trim Panel Replacement (Crew Cab). 4. Disconnect the electrical connector from the motor/actuator. 5. Remove the motor/actuator. 6. Push the cam assembly (2) forward until the timing hole (3) in the cam is aligned with the timing hole (4) in the lifter arm (1). 7. Insert a pin (1) in the holes to hold the position while installing the drive motor. Important: Both mechanisms should now be in the closed position. 8. Repeat this procedure for the opposite side. Installation Procedure Notice: Refer to Fastener Notice. 1. Install the sunroof window. Page 11549 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 7036 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 8959 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 24072 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch TRLR RT STOP/TURN PCB Relay Brake Lamp Relay: Locations TRLR RT STOP/TURN PCB Relay Electrical Center Identification Views Fuse Block - Underhood, Label Page 6376 4. Remove the CKP sensor bolt and sensor. Installation Procedure Important: When installing the CKP sensor, make sure the sensor is fully seated before tightening the bolt. A poorly seated CKP sensor may perform erratically and may set false diagnostic trouble codes (DTCs). Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CKP sensor, install a NEW O-ring seal onto the sensor. 2. Lubricate the O-ring seal with clean engine oil. Notice: Refer to Fastener Notice. 3. Install the CKP sensor and bolt. Tighten the bolt to 10 N.m (89 lb in). Page 12972 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 24305 1 - Door Frame 2 - Window Switch - Left Rear (A31) 3 - Window Motor - Left Rear (A31) 4 Speaker - Left Rear Door 5 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 6 Door Latch Assembly - Left Rear Right Rear Door (Crew Cab) Page 10911 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 5360 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 14577 Fluid Pressure Sensor/Switch: Service and Repair Allison - Automatic Transmission Pressure Switch Manifold Replacement Removal Procedure Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Caution: Refer to Battery Disconnect Caution. 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Page 4215 Notice: Refer to Fastener Notice. Important: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3). Tighten the TORX screw to 1.3 N.m (11.5 lb in). Important: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 1. Apply tire soap to the rubber portion of the valve stem (1). 2. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 10665 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Clip the line assembly to the frame. 3. Tighten the BPMV bolts. 4. Install the fuel/EVAP line bracket locator tab to the frame. 5. Install the fuel/EVAP line clips to the frame and crossmember. 6. Clip the inline electrical connector to the bracket. Notice: Refer to Fastener Notice. 7. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 N.m (80 lb in). 8. Install the fuel/EVAP line clip nut (2). Tighten the nut to 20 N.m (15 lb ft). 9. Remove the caps from the fuel and EVAP lines. 10. Connect the fuel tank EVAP line quick connect fitting to the chassis line. 11. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Page 17760 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Page 7080 Page 9915 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 8592 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 3008 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 11323 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6088 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 4677 Intake Manifold: Specifications Lower Intake Manifold Bolt First Pass in Sequence ........................................................................................................................ ....................................................... 3 N.m 27 lb in Second Pass in Sequence ................................... ................................................................................................................................... 12 N.m 106 lb in Final Pass in Sequence ................................................................................................................... .......................................................... 15 N.m 11 lb ft Upper Intake Manifold Stud First Pass ............................................................................................................................................. ...................................................... 5 N.m 44 lb in Final Pass .............................................................. .................................................................................................................................... 9 N.m 80 lb in Throttle Body Stud ............................................................................................................................... ........................................................... 9 N.m 80 lb in Page 2420 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 3973 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 9999 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 10595 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23935 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 23852 Page 5011 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 1616 Discharge Air Temperature Sensor / Switch: Diagrams HVAC Connector End Views Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Page 21863 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 5149 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 24189 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 9468 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 15883 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. I/P Fuse Block Fuse: Locations I/P Fuse Block Fuse Block - I/P, Label Page 3960 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 2884 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 10575 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 14010 Page 10848 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 2677 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 11658 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 23307 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 23596 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 21810 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 17444 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 5928 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 13568 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 12257 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 14437 For vehicles repaired under warranty, use the table. Disclaimer Page 887 Page 17692 Power Steering Fluid Cooler: Service and Repair Power Steering Fluid Cooler Replacement (With Hydroboost) Power Steering Fluid Cooler Replacement (With Hydroboost) Removal Procedure 1. Remove the radiator grille. 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. 3. Place drain pans under the vehicle as needed. Notice: Refer to Power Steering Hose Disconnected Notice. 4. Disconnect the power steering fluid cooler hose (3) from the steering gear (2). 5. Disconnect the power steering fluid cooler hose (4) from the power steering pump (1). 6. Remove the power steering fluid cooler bolts (2). 7. Remove the power steering fluid cooler (1) from the vehicle. Installation Procedure 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch Page 2311 1. Install a NEW MAP sensor seal to the MAP sensor, if necessary. 2. Install the MAP sensor (2) to the upper intake manifold. Notice: Refer to Fastener Notice. 3. Install the MAP sensor bolt (1). Tighten the bolt to 10 N.m (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the MAP sensor. Page 19095 Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Page 606 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9293 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 7280 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 5945 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Locations Entertainment System Control Module: Locations Entertainment/Communication Component Views Headliner and Overhead Console (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infrared Module (U42) 4 - Emergency Vehicle Wiring Blunt Cuts (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Page 24695 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 17596 D Height Measurement Important: The left and right D height difference should be no more than 14 mm (0.55 in). Use the following procedure to measure the D height. 1. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. Measure between the axle bracket and jounce bumper mount bracket as shown in graphic. 5. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 6. Gently remove your hands and let the vehicle settle. 7. Repeat this operation 2 more times for a total of 3 times. 8. Re-measure the D height as in step 4. 9. The true D height is the average of the measurement from step 4 and step 8. The side to side difference in D height must not exceed 14 mm (0.55 in). 10. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Page 2798 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) Pinion Flange: Service and Repair Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) Drive Pinion Flange/Yoke and/or Oil Seal Replacement (All Except 9.75 Inch Axle) Tools Required * J 8614-01 Flange/Pulley Holding Tool * J 22388 Rear Axle Pinion Oil Seal Installer - Rear (8.6 inch, 9.5 inch axle) * J 44414 Rear Axle Pinion Oil Seal Installer (10.5 inch, 11.5 inch axle) Removal Procedure Important: Observe and mark the positions of all the driveline components, relative to the propeller shaft and the axles, prior to disassembly. These components include the propeller shafts, drive axles, pinion flanges, output shafts, etc. Reassemble all the components in the exact places in which you removed the parts. Follow any specifications, torque values, and any measurements made prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies (8.6 inch, 9.5 inch axles). 3. Remove the rear brake calipers (8.6 inch, 9.5 inch axles). 4. Remove the brake rotors (8.6 inch, 9.5 inch axles). 5. Remove the axle shafts (10.5 inch, 11.5 inch axle). 6. Reference mark the rear propeller shaft (3) to the rear axle pinion yoke (4). 7. Disconnect the propeller shaft from the axle. Wrap the bearing caps with tape in order to prevent the loss of bearing rollers. Support the propeller shaft as necessary. 8. Measure the amount of torque required to rotate the pinion. Use an inch-pound torque wrench. Record this measurement for reassembly. This will give the combined preload for the following components: * The pinion bearings * The pinion pilot bearing (10.5 inch axle) * The pinion oil seal * The differential case bearings * The axle bearings (8.6 inch, 9.5 inch axles) * The axle seals (8.6 inch, 9.5 inch axles) Page 5042 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7805 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 10603 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 1981 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 9386 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 11789 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Page 2599 Page 2727 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 15355 4. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Important: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Page 6146 Page 531 Page 22430 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 9384 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 23140 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 205 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 11976 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 16229 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 12671 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 11731 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 9743 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Locations Manifold Pressure/Vacuum Sensor: Locations Engine Controls Component Views Rear of the Engine 1 - Central Sequential Fuel Injection (SFI) Module 2 - Manifold Absolute Pressure (MAP) Sensor 3 G106 4 - Engine Oil Pressure (EOP) Sensor 5 - Ignition Control Module (ICM) 6 - G107 Page 23580 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 17065 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 9245 Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CMP sensor, install a NEW O-ring seal onto the sensor. 2. Install the CMP sensor to the wiring harness jumper. 3. Connect the CMP sensor wiring harness jumper to the CMP sensor. 4. Lubricate the O-ring seal with clean engine oil. 5. Install the CMP sensor and wiring harness jumper to the engine front cover. Notice: Refer to Fastener Notice. 6. Install the CMP sensor bolt. Tighten the bolt to 10 N.m (89 lb in). 7. Install the water pump. 8. Connect the engine wiring harness electrical connector (7) to the CMP sensor wiring harness jumper. Page 20044 Speaker - Right Rear Door (Extended Cab/Crew Cab +UQA) Speaker - Subwoofer (UQA) Page 7033 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 23210 Dimmer Switch: Diagrams Lighting Systems Connector End Views Headlamp and Panel Dimmer Switch Page 230 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 12267 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7560 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 2998 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 735 Page 10210 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 22220 Page 10466 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 10123 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Page 3886 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 4222 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 20914 Owner Letter Owner Letter July 2010 Dear GM Customer: As the owner of a 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, or Yukon XL vehicle, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles may have a peeling condition on the top surface of the front or rear chrome interior door handle(s) that could create a rough edge. A chrome plating irregularity combined with direct sunlight exposure may cause the plating to separate from the top surface of the handle. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners of 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles with additional protection for the front and rear chrome interior door handles. If this condition occurs on your 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, or Yukon XL within 10 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by July 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. Scott Lawson Director, Customer and Relationship Services Enclosure 09239 Page 12160 Page 23411 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 7910 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 16281 Part 2 Electrical Center Identification Views Junction Block - Right I/P, Top View Junction Block - Right I/P (Wire Entry) Page 2228 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 11654 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 20535 Parts Information Disclaimer Page 2410 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 8145 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 471 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 3209 Page 19150 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 10234 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 17055 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 3825 corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). Page 6138 Battery Current Sensor: Diagrams Battery Current Sensor (10 Series) Battery Current Sensor (10 Series) Page 6648 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 17670 7. Install the runout gauge at the idler arm. 8. Push the tire inward slowly with one hand to remove any lash. Zero out the runout gauge and pull outward in order to take a reading. 9. Allow only 1 mm (0.039 in) of movement at the idler arm ball stud. If the movement is more than 1 mm (0.039 in) then replace the idler arm. Page 2672 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 18173 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 4911 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 9226 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 12959 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 21972 5. Install the water trough to the sunroof from the top of the vehicle. Notice: Refer to Fastener Notice. 6. Install the screws (1) that retain the water trough to the sunroof. Tighten the screws to 1 N.m (9 lb in). 7. Install the sunroof window. Page 16768 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 13030 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 4764 Fuel Pressure: Service Precautions Relieving Fuel Pressure Caution Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 9288 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 15587 Electronic Brake Control Module (JF3/JF7) Page 21513 Page 8332 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 5120 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 24099 1. Remove the instrument panel (I/P) knee bolster. Refer to Knee Bolster Replacement in SI. 2. Remove the park brake release handle. Refer to Park Brake Release Handle Assembly Replacement SI. 3. Locate the left bussed electrical center (LBEC), which is located on the left end of the instrument panel IP. 4. Locate the 40-way connector X1 that is attached to the back of the LBEC. 5. Disconnect the 40-way connector X1 from the LBEC. Page 11056 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 5913 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 20968 For vehicles repaired under warranty, use the table. Disclaimer Page 10223 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 12727 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Locations Impact Sensor: Locations SIR Component Views Front Sensors +10 Series 1 - Hood 2 - Inflatable Restraint Front Sensor - Left 3 - Inflatable Restraint Front Sensor - Right Left Front of the Engine Compartment (-10 Series) Page 13263 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: * M6 X 1.0 X 65.0 (1) * M6 X 1.0 X 54.4 (2) * M6 X 1.0 X 47.5 (3) * M6 X 1.0 X 35.0 (4) * M8 X 1.0 X 20.0 (5) * M6 X 1.0 X 12.0 (6) * M6 X 1.0 X 18.0 (7) Page 12545 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 256 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9269 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 15759 5. Remove the positive battery cable connector (1) from the underhood bussed electrical center (UBEC). 6. Remove the mega fuse cover. Locations Battery Current Sensor: Locations Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor Page 22467 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 7603 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 11301 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 2776 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 8975 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 11072 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 14806 Page 227 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 6063 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 8943 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8483 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 12554 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 13245 Notice: Refer to Component Fastener Tightening Notice. 9. Install the drain plug (7) and drain plug seal (6). Tighten the drain plug to 35 N.m (26 lb ft). 10. Lower the vehicle. Notice: Use only clean and approved transmission fluid. 11. Refill the transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. Important: Remember fluid remains in the external circuits and transmission cavities after draining the transmission. 12. Check the transmission fluid level. Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 12875 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 9935 Page 18946 When in the correct location, the latch plate tongue will be between the webbing and the seat. U.S. dealers: For additional information, search gmtraining.com's Web Video Library for the May 2007 Emerging Issues video (course #10207.05D). Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9195 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 18883 Malfunction Lamp / Indicator: Service and Repair Inflatable Restraint Instrument Panel Module Indicator Replacement Page 1924 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11846 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Electrical - Various Electrical System Malfunctions Wiring Harness: Customer Interest Electrical - Various Electrical System Malfunctions Bulletin No.: 06-08-45-009 Date: October 31, 2006 TECHNICAL Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on one or all of the following conditions: Rear door locks inoperative Rear windows inoperative Door courtesy lamps inoperative or stay on at times Rear speakers inoperative Any fuse (related to the rear doors) that is blown/shorted SIR codes related to the pretensioner Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction This repair operation is intended to be done on both B-pillars. Remove the lower B-pillar cover. Disconnect the Supplemental Inflatable Restraint (SIR) connector. Inspect the wiring harness in the B-pillar around the seat belt retractor. Make any necessary wiring harness repairs. Wrap the "entire" harness with electrical tape. Install conduit tubing around the harness. Locations Torque Converter Clutch Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 6830 Vehicle Speed Sensor: Locations Power Take-Off Power Take-Off (PTO) Component Views Front Frame Rail 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor 4 - Automatic Transmission Input Shaft Speed (AT ISS) Sensor 5 - Automatic Transmission 6 - Vehicle Speed Sensor (VSS) 7 - X124 8 - Power Take Off (PTO) Module 9 - X175 Page 14501 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 7371 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 24191 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 14922 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 7432 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (3) up and over the knock sensor. 4. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 5. Lower the vehicle. Page 11353 Page 18853 Seat Position Sensor: Diagrams SIR Connector End Views Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) Page 18776 1 - Door Frame 2 - Window Switch - Left Rear (A31) 3 - Window Motor - Left Rear (A31) 4 Speaker - Left Rear Door 5 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 6 Door Latch Assembly - Left Rear Right Rear Door (Crew Cab) Page 12814 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Capacity Specifications Refrigerant: Capacity Specifications Refrigerant System Capacities Page 14358 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 4934 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 12249 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 180 Page 15862 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 6380 Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face the engine front cover. Failure to do so will damage the front cover and the reluctor ring. 1. Install the CKP sensor reluctor ring. 1. Align the keyway on the CKP sensor reluctor ring with the key in the crankshaft. 2. Using J 5590, push the CKP sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. 2. Install the engine front cover. Page 17294 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Allison - Automatic Transmission Transmission Mode Switch: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 15868 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 11661 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 4970 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 24744 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 9155 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 5861 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 6537 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 303 Memory Seat Module X5 (AN3) Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Restraints - Air Bag Readiness Light On. Malfunction Lamp / Indicator: All Technical Service Bulletins Restraints - Air Bag Readiness Light On. TECHNICAL Bulletin No.: 09-09-41-005 Date: June 26, 2009 Subject: Air Bag Readiness Light On, Service Air Bag Message, Inflatable Restraint Sensing and Diagnostic Module (SDM) Corrosion (Replace SDM/Cut and Remove Carpet Pad) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the Air Bag Readiness Light is on. There may also be a Service Air Bag Message on the Driver Information Center (DIC). Upon further investigation, the Sensing and Diagnostic Module (SDM) may be corroded. Cause This condition may be caused by an unseated parking brake cable grommet causing water intrusion under the carpet or vinyl floor, resulting in wet padding. Power washing the vinyl floor and/or customer snow boots can introduce water to the padding above the SDM area. As the padding gets wet, water wicks through the padding towards the SDM over time. Over an extended period of time of constant exposure to water with potential salt/calcium and other elements, the SDM surface starts to corrode. Correction 1. Replace the SDM per SI procedures. Refer to Inflatable Restraint Sensing and Diagnostic Module Replacement in SI. 2. Inspect the SDM connector for corrosion. If corrosion is evident, repair or replace the connector. Refer to SIR/SRS Wiring Repairs in SI. 3. Verify the parking brake cable grommet is sealed properly. Important Cut and remove the padding from around the SDM as instructed whenever the SDM is serviced even if no corrosion is evident to prevent future moisture and corrosion to the SDM and connector. 4. Cut and remove padding from the area around and above the SDM. Refer to illustration above. Make an addition cut to remove all of the padding above the SDM. Parts Information Refer to Group Number 16.712 (Inflatable Restraint System) of the GM Parts Catalog for the appropriate service parts. Warranty Information For vehicles repaired under warranty, use the table above. Page 10379 Page 1561 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Page 2632 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 7573 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 947 Body - L/H/R/H Power Mirror(s) Inoperative Wiring Harness: Customer Interest Body - L/H/R/H Power Mirror(s) Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5781 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 7553 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 24423 Front Door Window Regulator: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Page 1810 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 7042 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 418 Page 10630 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 19618 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Page 9591 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11940 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8295 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 9884 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 461 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 12073 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 5816 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 8870 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 4755 10. Remove the CMP sensor bolt. 11. Remove the CMP sensor and wiring harness jumper from the engine front cover. 12. Disconnect the CMP sensor wiring harness jumper from the CMP sensor. 13. Remove the CMP sensor from the wiring harness jumper. 14. Remove the front cover bolts. Important: After the composite front cover is removed do not reinstall the front cover. Always install a NEW front cover. 15. Remove and discard the front cover. 16. Clean all sealing surfaces. Installation Procedure Page 11608 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 15775 6. Install the battery. Page 8566 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 24537 Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. "An unattended (vehicle parked - key not in the "ON" position) under hood fire that can occur at any time and possibly involve nearby vehicles or structures." If the customer still refuses, provide the customer with a copy of the "Notice to Customer" document contained in this bulletin, record "customer declined recall repair" on the repair order and, if possible, have the customer sign the repair order. Retain this repair order at the dealership. Page 14913 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 1753 Turn Signal Switch: Diagrams Lighting Systems Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Page 3637 Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the air cleaner outlet resonator from the MAF/IAT sensor. 3. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. Page 16224 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 5933 View of the connector when released from the component. View of another type of Micro 64 connector. Page 12808 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 5169 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Service Precautions Fuel Rail: Service Precautions Fuel Rail Stop Bracket Installation Caution Caution: The fuel rail stop bracket must be installed onto the engine assembly. The stop bracket serves as a protective shield for the fuel rail in the event of a vehicle frontal crash. If the fuel rail stop bracket is not installed and the vehicle is involved in a frontal crash, fuel could be sprayed possibly causing a fire and personal injury from burns. Page 16197 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11577 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 6646 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 5270 Page 2830 Page 13163 17. Remove the oil level indicator tube, if equipped with RPO HP2. 18. Remove the seal from the transmission, if necessary. Installation Procedure 1. Install a NEW seal to the indicator tube. 2. Install the oil level indicator tube, if equipped with RPO HP2. Page 16072 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 590 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Wipers/Washers - Washer Fluid Leak on The Driver's Side Windshield Washer Pump: Customer Interest Wipers/Washers - Washer Fluid Leak on The Driver's Side INFORMATION Bulletin No.: 08-08-43-006 Date: April 08, 2008 Subject: Information on Windshield Washer Solvent Leaking Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali If a customer comments that there is windshield washer solvent leaking from the front drivers side of the vehicle this condition may be caused by a cut or not properly seated washer pump grommet. Before replacing the washer pump inspect the condition of the grommet around the inlet of the washer pump. First make certain that the pump/grommet is fully seated in the washer solvent container. If a leak still exists then remove the pump from the container using care not to tear or cut the grommet during removal and inspect the grommet to make sure it's free of cuts or tears. Install the pump and grommet back into the container making sure to use washer solvent to lubricate the grommet. Inspect for leaks again. If the washer solvent still leaks be sure to inspect the outlet hose for a proper connection. Make every effort to inspect all components before ordering a new part. DO NOT replace the washer pump unless you see that the pump is cracked or broken externally. If the grommet is torn or cut replace only the grommet. Disclaimer Page 12882 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 23062 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Roof Marker Lamp Replacement (U01) Marker Lamp: Service and Repair Roof Marker Lamp Replacement (U01) Roof Marker Lamp Replacement (U01) Page 20626 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 08-08-64-007 Date: 080513 Body - Outside Door Handle(s) Squeak When Operated TECHNICAL Bulletin No.: 08-08-64-007 Date: May 13, 2008 Subject: Squeaky Outside Door Handle (Grease U-Channel of Handle) Models: 2007-2008 Cadillac Escalade, Escalade EXT, Escalade ESV 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Condition Some customers may comment on a squeak noise coming from the door handle as the handle is actuated. Cause This condition may be caused by the pin and the inside of pawl surface making contact with each other, resulting in a squeak noise. Correction DO NOT REPLACE THE DOOR HANDLE. 1. Remove the fasteners to the door handle, leaving the rod to the latch attached. 2. Apply a generous amount of dielectric silicone grease, P/N 12345579 (in Canada, 10953481), as shown in the graphics, into the U-channel of the Page 10383 Page 11589 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 24243 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 3026 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 13766 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 4700 28. If required, remove the EVAP canister purge solenoid valve studs. 29. Remove the purge solenoid valve. 30. Clean and inspect the intake manifold - upper, if necessary. Refer to Intake Manifold Cleaning and Inspection. Installation Procedure 1. If required, install the purge solenoid valve. Notice: Refer to Fastener Notice. 2. Install the EVAP canister purge solenoid valve studs. If reusing the old studs, apply threadlock to the threads. Refer to Sealers, Adhesives, and Lubricants for the correct part number. Tighten the studs to 10 N.m (89 lb in). Page 11430 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 1676 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the negative battery cable. 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 23114 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 12636 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. Tighten the bolt to 12 N.m (108 lb in). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Page 9080 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 8458 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 2550 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Control Module: Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 12493 Pressure Regulating Solenoid: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control (PC) Solenoid Valve, Wiring Harness Side Page 7282 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 19909 Page 24172 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 7424 Knock Sensor: Description and Operation Knock Sensor (KS) System Description Purpose The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor (KS) system uses one or 2 flat response 2-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the control module through a low reference circuit. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Page 20468 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 20264 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1131 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 2361 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 21834 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 2093 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 16698 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 9180 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 23093 View of the connector when released from the component. View of another type of Micro 64 connector. Page 21603 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 16761 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 3180 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (3) up and over the knock sensor. 4. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 5. Lower the vehicle. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 9094 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 6345 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 1019 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 2154 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 14857 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 11154 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 5449 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Locations Knock Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 14936 Page 2545 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 1517 Sunroof / Moonroof Switch: Diagrams Sunroof Connector End Views Sunroof Switch Page 6336 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 1012 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 9401 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 4225 Page 16445 X112 Inline Harness Connector End Views X112 Engine Harness to Camshaft Position Sensor Jumper Harness (4.3L/4.8L/5.3L) Page 9844 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 9323 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 18327 The concern must be current before diagnosis can be performed. Review and print the following SI documents - Electrical Center Identification Views, for use during diagnosis: - Junction Block - Right I/P, Top View - Junction Block - Right I/P X4 - Junction Block - Right I/P X5 Locate the Junction Block - Right Side IP on the vehicle. For the appropriate actuator, measure the following signals for voltage/resistance from the BACK of the X4 or X5 connector and record the following: DO NOT unplug the X4/X5 connector. Turn Ignition On, A/C Blower Full, if possible - mode on "panel" and Temp to "cold." Once the fault is removed, the actuator will stay in default position until commanded to a new position. Change commanded position regularly to see if the issue is still current. Continue to monitor door positions (feedback) on Tech2 to see if it changes during circuit testing. - Ignition Voltage - 12V - Door Control Signal - 2.5V when stationary, OV when commanded toward "cold" or "panel", 5V when commanded toward "hot" or "defrost" - Low Reference - less than 40 ohm with ignition on. Less than 10 ohm with ignition off - Door Position Signal - measure voltage - 5 Volt Reference - 5V If any signals do not display the correct value or if the issue is corrected during testing, pull the connector and check the terminal for poor tension (use the appropriate terminal tool). Replace or repair the terminal if poor tension is found. If all signals are correct at RH BEC, reconfirm the customer's comments. If the condition is not present, no further repairs are necessary. If the condition is still present, recheck the actuator connector 5 volt reference circuit, pin drag test and repair connector/pin as necessary. Warranty Information For vehicles repaired under Enqineerinq direction, use the table. Page 19026 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11855 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 21683 Power Door Lock Relay: Locations Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Disassembled Views Control Valve Body Assembly (1 of 2) Control Valve Body Assembly 350 - Control Valve Body Assembly 353 - Forward Accumulator Oil Seal 354 - Forward Accumulator Piston 355 - Forward Accumulator Pin 356 - Forward Accumulator Spring 357 Forward Abuse Valve 358 - Forward Abuse Valve Spring 359 - Bore Plug 360 - Coiled Spring Pin 360 - Coiled Spring Pin 361 - Low Overrun Valve 362 - Low Overrun Valve Spring 363 - Forward Accumulator Cover 364 - Forward Accumulator Cover Bolt 364a - Pressure Control Solenoid Retainer Bolt 365 - 1-2 Shift Valve Spring - Model Dependent 366 - 1-2 Shift Valve - Model Dependent 367a - 1-2 Shift Solenoid Valve 367b - 2-3 Shift Solenoid Valve 368 - 2-3 Shift Valve 369 - 2-3 Shuttle Valve 370 - 1-2 Accumulator Valve Spring 371 - 1-2 Accumulator Valve 372 - 1-2 Accumulator Valve Sleeve Page 18080 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16124 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 14883 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 9519 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 10558 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12908 Shift Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 6L50/6L80/6L90 - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Page 7131 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 24687 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 11485 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose in order to remove the spark plug wire boot from the spark plug. 3. Open the spark plug wire separators (1). 4. Remove the appropriate spark plug wire(s). Installation Procedure Notice: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 1. If reinstalling the old spark plug wires, apply dielectric grease GM PN 12345579 (Canadian PN 10953481), or equivalent to the inside the spark plug wire boots. 2. Install the appropriate spark plug wire(s) 3. Close the spark plug wire separators (1). 4. Install the appropriate spark plug wire boot(s) (2) to the spark plug. (left side shown, right similar). Exhaust System - Catalytic Converter Precautions Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Precautions Bulletin No.: 06-06-01-010A Date: February 04, 2008 INFORMATION Subject: Information on Close-Coupled Converter and Engine Breakdown or Non-Function Due to Severe Overheat or Lack of Oil Causing Piston(s) Connecting Rod(s) Crankshaft Cylinder(s) and/or Head(s) Camshaft(s) Intake and/or Exhaust Valve(s) Main and/or Rod Bearing(s) Damage Models: 2004-2008 GM Passenger Cars and Trucks with Close-Coupled Catalytic Converters Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-06-01-010 (Section 06 - Engine/Propulsion System). Certain 2004-2008 General Motors products may be equipped with a new style of catalytic converter technically known as the close-coupled catalytic converter providing quick catalyst warm-up resulting in lower tail pipe emissions earlier in the vehicle operating cycle. If an engine breakdown or non-function were to occur (such as broken intake/exhaust valve or piston) debris may be deposited in the converter through engine exhaust ports. If the engine is non-functioning due to a severe overheat event damage to the ceramic "brick" internal to the catalytic converter may occur. This may result in ceramic debris being drawn into the engine through the cylinder head exhaust ports. If a replacement engine is installed in either of these instances the replacement engine may fail due to the debris being introduced into the combustion chambers when started. When replacing an engine for a breakdown or non-function an inspection of the catalytic converters and ALL transferred components (such as exhaust/ intake manifolds) should be performed. Any debris found should be removed. In cases of engine failure due to severe overheat dealers should also inspect each catalytic converter for signs of melting or cracking of the ceramic "brick". If damage is observed the converter should be replaced. Disclaimer Page 9779 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13985 Page 15653 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement (JD9, JF3, JF7) Page 6739 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 11128 Page 622 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 16983 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 21249 Close the passenger door. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13336 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 7416 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 21199 Transmission Support Crossmember Replacement (4WD 1500/2500) Transmission Support Crossmember Replacement (4WD 1500/2500) Page 5782 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 403 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 22147 Power Seat Motor: Service and Repair Front Seat Recliner Actuator Motor Replacement Front Seat Recliner Actuator Motor Replacement The front seat recliner actuator motor is serviced as part of the seat back assembly. If the actuator motor needs to be replaced the entire seat back frame kit will need to be installed. Refer to Front Seat Back Frame Replacement. Page 11196 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 6861 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 7352 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 10869 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 16263 Fuse Block - I/P X3 Page 12256 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 13436 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). Tighten the bolts to 10 N.m (89 lb in). Ball Check Valves 5. Install the 7 checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Page 14320 Page 4003 Fuse Block: Locations HVAC - Automatic HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor Page 10611 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components Refer to SIR Identification Views. There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. Page 17297 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) Page 7951 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 3870 Page 10406 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 19715 Diagnostic Tips Review # 3 - Denso Navigation Radios Page 12954 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 2879 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 14666 Clutch Control Solenoid Valve: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 3. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) Page 8184 Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: Customer Interest Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 6929 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 11897 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 4801 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Page 16925 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 1921 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 5444 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 8310 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 7258 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 2862 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 3020 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Ball Joint Inspection (Lower Ball Joint) Ball Joint: Testing and Inspection Ball Joint Inspection (Lower Ball Joint) Ball Joint Inspection (Lower Ball Joint) Tools Required J 8001 Dial Indicator Set 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. With the wheel and tire on the vehicle, lift the suspension corner by hand to determine if any looseness is present. If vertical free play is experienced proceed with the following instructions. 3. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation. 4. Clean and inspect the ball joint seals for cuts or tears. If the ball joint seals are damaged, replace the ball joint. Refer to Lower Control Arm Ball Joint Replacement. 5. Install and position the dial indicator from J 8001 against the end of the ball joint. Important: Do not pry between the lower arm and the wheel drive shaft boot or in such a manner that the ball joint seal is contacted. Damage to the wheel drive shaft boot will result (4WD). 6. Gently lift or pry the suspension upward then let it settle. 7. The dial indicator reading should be no more than 2 mm (0.079 in). If the reading is out of specification, replace the ball joint. Page 18500 8. Remove the nuts (2) from the HVAC module (3). 9. Remove the bolts (1) from the HVAC module (3). 10. Remove the HVAC module (3). Installation Procedure 1. If replacing the HVAC module, transfer the components from the old HVAC module as necessary. 2. Install the HVAC module (3). Notice: Refer to Fastener Notice. 3. Install the nuts (2) to the HVAC module (3). Tighten the nuts to 9 N.m (80 lb in). 4. Install the bolts (1) to the HVAC module (3). Page 12595 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 4023 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 7021 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 14298 7. Place a brass drift against the CV joint cage (1). 8. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 9. Install the first chrome alloy ball (2) when the CV joint cage (1) tilts. 10. Tilt the CV joint cage (1) in the opposite direction to install the opposing chrome alloy ball (2). 11. Repeat this process in order to install all six of the balls. Page 17533 Disclaimer Page 20129 Disclaimer Page 10934 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 18495 2. Install the evaporator tube nut to the condenser. Tighten the nut to 16 N.m (12 lb ft). 3. Connect the evaporator tube to the auxiliary A/C tube using new sealing washers, if equipped. 4. Install the evaporator tube nut to the auxiliary A/C tube, if equipped. Tighten the nut to 16 N.m (12 lb ft). 5. Install the evaporator tube to the evaporator. 6. Install the evaporator tube nut to the evaporator. Tighten the nut to 16 N.m (12 lb ft). 7. Install the surge tank hold down nut and bolt and position aside. 8. Install the air cleaner assembly. 9. Install the upper radiator air baffle and deflector. 10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging. 11. Leak test the fittings of the components using the J 39400-A. Page 11058 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 12761 Clutch Control Solenoid Valve: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 19706 Diagnostic Tips Review Table Exhaust Manifold Heat Shield Replacement - Right Side Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Right Side Exhaust Manifold Heat Shield Replacement - Right Side (4.3L) 1. Remove the spark plug wires. 2. Reposition the spark plug wires out of the way, if necessary. 3. Remove the exhaust manifold heat shield bolts and heat shield from the exhaust manifold. Installation Procedure Notice: Refer to Fastener Notice. 1. Position the exhaust manifold heat shield to the exhaust manifold and install the heat shield bolts. Tighten the bolts to 9 N.m (80 lb in). Page 10958 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 5814 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 2506 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 4020 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 15929 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 7238 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 11803 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Interior - Front Power Seat Adjust/Memory Inoperative Power Seat Switch: All Technical Service Bulletins Interior - Front Power Seat Adjust/Memory Inoperative Bulletin No.: 06-08-50-012 Date: October 06, 2006 TECHNICAL Subject: Front Driver or Passenger Power Seat Adjust Functions Inoperative and/or Driver Seat Memory Inoperative (Check Power Seat Switch Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (New Style), Suburban, Tahoe 2007 GMC Sierra (New Style), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the front driver or passenger power seat adjust functions are inoperative. They may also comment that the driver seat memory is inoperative. Cause The cause of this condition may be due to the power seat switch connector not being fully seated. Correction Remove the front seat cushion outer trim panel following the replacement procedure in SI. Verify that the power seat switch connector is fully seated. Reseat the connector and test the seat functions. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16424 X303 Body Harness to Driver Seat Harness (-AN3) Page 23439 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. 3. Dismount the tire from the rim. Important: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 22956 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 2148 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 2066 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 15691 Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement (JH6, JH7) Front Wheel Speed Sensor Replacement (JH6, JH7) Page 8610 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 16261 Page 6261 lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If re-installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. Notice: Refer to Fastener Notice. 2. Install the ECT sensor to the cylinder head. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 1070 Vehicle Zoning Strategy Truck Zoning Page 14802 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 21293 Disclaimer Page 10543 Fuel Pump Relay: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 22217 Rear Seat Back Cushion Frame Replacement (Extended Cab with A68) Rear Seat Back Cushion Frame Replacement (Extended Cab with A68) Interior - Excessive Wind Noise In Interior Of Vehicle Sound Proofing / Insulation: All Technical Service Bulletins Interior - Excessive Wind Noise In Interior Of Vehicle TECHNICAL Bulletin No.: 10-08-58-001E Date: March 08, 2011 Subject: Excessive Wind Noise Coming from Rear Interior of Vehicle (Perform Repair as Outlined) Models: 2007-2011 Chevrolet Silverado Crew Cab and Extended Cab 2007-2011 GMC Sierra Crew Cab and Extended Cab Supercede: This bulletin is being revised to update the repair in the Customer Enthusiasm section and update the Parts Information. Please discard Corporate Bulletin Number 10-08-58-001D (Section 08 - Body and Accessories). Condition Some customers may comment on hearing excessive wind noise coming from the rear interior of the vehicle. Cause #1 This condition may be caused by a void in the body filler within the C-pillar. Cause #2 This condition may be caused by the body rear panel acoustic insulator that is mounted behind the rear seat. There is an access flap (1) in this panel that could cause excessive noise if the flap is not fully seated/closed into the rest of the insulator material. Also, starting in 2010, a new insulator was installed that may allow higher wind/road or other acoustic noise that may be objectionable for some customers. Noise penetration into the cab can be higher than a similarly equipped 2009, or earlier, model. As shown in the graphic above, note that the service part insulator (1) is noticeably thicker than the original 2010 part (2). Correction #1 Note This repair is specific to 2007-2010 model years. Page 5062 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 14276 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Tools Required * J 8059 Snap Ring Pliers * J 35910 Drive Axle Seal Clamp Pliers * J 36652-1 Drive Axle Clamp Swage Tool * J 36652-2 Axle Swage Tool Removal Procedure 1. Remove the wheel drive shaft. 2. Remove the wheel drive shaft seal cover, if applicable. Important: Use caution when using the hand grinder by the CV joint outer race (1). 3. Use a hand grinder to cut through the swage ring (2). 4. Use side cutters to cut off the small boot clamp (4). Page 9228 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 2119 Page 13133 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 22987 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 23783 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 557 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 7622 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 5939 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 21872 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 13493 Transmission Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Turbine Speed Sensor Page 6283 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 17774 Page 12561 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 6046 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 6189 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11588 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 17635 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Page 6239 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 12874 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 14210 Seals and Gaskets: Service and Repair Rear Axle Housing Cover and Gasket Replacement Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the rear axle. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Remove the rear axle housing cover (2) from the axle housing. 1. Catch the oil in a drain pan. 2. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. Installation Procedure 1. Install the rear axle housing cover (2) and a new gasket. Notice: Refer to Fastener Notice. Important: Do not reuse the rear axle housing cover bolts. 2. Install the new rear axle housing cover bolts (1). Tighten the rear axle housing cover bolts in a crosswise pattern to 40 N.m (30 lb ft). 3. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. 4. Lower the vehicle. Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Disc) Page 10635 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 2284 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 14191 1. Install the ring gear to the differential case. Important: The ring gear bolts on the 8.6 inch and the 9.5/9.5LD inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. 2. Install the new ring gear bolts. Hand start each bolt to ensure that the ring gear is properly installed to the differential case. Notice: Refer to Fastener Notice. 3. Tighten the ring gear bolts, Tighten the ring gear bolts alternately and in stages, gradually pulling the ring gear onto the differential case. * For the 8.6 inch axle, tighten the ring gear bolts in sequence to 120 N.m (89 lb ft). * For the 9.5/9.5LD inch axles, tighten the ring gear bolts in sequence to 140 N.m (103 lb ft). * For the 11.5 inch axle, tighten the ring gear bolts in sequence to 237 N.m (175 lb ft). 4. Install the pinion bearing cups. 5. Determine the selective shim thickness for the pinion gear. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Pinion Depth Adjustment (10.5 Inch Axle). 6. Install the selective shim onto the pinion. 7. Install the inner pinion bearing to the pinion. 8. Install a new collapsible spacer. 9. Lubricate the pinion bearings with axle lubricant. Refer to Fluid and Lubricant Recommendations. 10. Install the outer pinion bearing into the axle housing. 11. Install the new pinion oil seal. 12. Install the pinion into the axle housing. 13. Install the pinion yoke. 14. Install the differential assembly. 15. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 16. Lower the vehicle. Page 13416 Seals and Gaskets: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement Tools Required * J 43911 Selector Shaft Seal Remover * J 43909 Selector Shaft Seal Installer Removal Procedure 1. Remove the park/neutral position (PNP) switch. 2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. 3. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to ensure that the removal tool is firmly attached to the seal shell. 4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore. Page 9660 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 13025 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 13592 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 12269 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 13528 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 14231 23. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. Installation Procedure 1. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). 2. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). 3. Install the inner pinion bearing using the J 24433. Press the bearing on until the cone seats on the pinion. 4. Install a new collapsible spacer. 5. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Page 5331 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 12319 Transmission Control Module (TCM) 80-Way Connector (Part 1) Locations Seat Heater Switch: Locations Power Seat Component Views Memory/Heated Seat Switch 1 - Outside Rearview Mirror (OSRVM) - Driver 2 - Memory/Heated Seat Switch (AN3) Page 8197 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 7079 Page 7824 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 7240 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 16431 X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW/5X7/5Y0) to Right A-Pillar Harness (CF5/TRW/5X7/5Y0) X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness Page 11387 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 9482 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 8412 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 6753 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 19088 10. Mount the seat belt pretensioner (1) in the SIR deployment fixture (3) with the open end facing up using the following mounting method. * Adjust and secure the J 39401-B arms (4) to the deployment fixture. * To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the seat belt pretensioner (1) to the deployment fixture brackets. * Securely tighten all fasteners prior to deployment. 11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 12. Short the 2 SIR deployment harness (1) leads together using 1 banana plug seated into the other. 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness. 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the seat belt pretensioner connector (1) to the adapter (2) on the deployment harness (3). Important: When deploying a seat belt pretensioner, the rapid expansion of gas is very loud. Notify the people in the immediate area that a seat belt pretensioner will be deployed. 16. Clear the area of people. Page 11203 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 15760 7. Remove the starter solenoid cable nut (2) from the mega fuse. 8. Remove the starter solenoid cable (1) terminal from the mega fuse stud. 9. Remove the positive battery cable channel from the studs on the plenum front panel. 10. Remove the positive battery cable clips from the studs on the plenum front panel. Page 16780 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Interior - Cleaning Interior Surfaces of Vehicle Carpet: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Page 2213 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 10808 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 7940 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Diagrams Brake Booster Vacuum Sensor: Diagrams Brake Booster Vacuum Sensor (JL4) Brake Booster Vacuum Sensor (JL4) Page 15003 Transmission Control Module (TCM) 80-Way Connector (Part 2) Page 1138 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Locations Accelerator Pedal Position Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 20401 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Diagrams Power Mirror Switch: Diagrams Mirror Connector End Views Outside Rearview Mirror Switch (DL8/DPN) Page 11804 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 3142 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 22997 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 22006 5. Slide the water gutter rearward to release the retaining tabs (1) from the slots (2) in the track. 6. Remove the water gutter (3) from the track. Installation Procedure 1. Position the sunroof water gutter to the sunroof window track. 2. Seat the retaining tabs (1) on the water gutter (3) into the slots (2) in the track, and push the water gutter forward until the retaining tabs lock into place. 3. Ensure that all 6 tabs are secured. Page 2946 Vehicle Zoning Strategy Truck Zoning Page 10017 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 24534 Page 23603 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 7566 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 19920 Diagnostic Tips Review # 3 - Denso Navigation Radios Page 23923 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 23563 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 23120 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 965 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 8456 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 13576 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 11570 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 10556 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 131 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 22932 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2495 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 9046 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 23091 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 7024 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 24436 Important: Use a suitable tool to release the tabs (1) from the rear sliding window pulley (3). 4. Remove the rear sliding window pulley covers (2). 5. Remove the regulator cables (2) from the retainers (1) located across the bottom edge of the window frame. 6. Remove the screw (1) from regulator (2). 7. Remove the regulator (2) from the motor/module. Page 10037 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 3749 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: - Give freezing protection down to -34°F (-37°C). - Give boiling protection up to 265°F (129°C). - Protect against rust and corrosion. - Help keep the proper engine temperature. - Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Page 3525 Disclaimer Page 12080 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21310 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Page 17111 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 22587 1 - Door Lock Switch - Passenger 2 - Door Latch Assembly - Passenger 3 - Speaker - Right Front Page 9728 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 17243 For vehicles repaired under warranty, use the table. Disclaimer Page 23149 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 16728 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 602 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 6337 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 10696 12. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 13. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line. 14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 15. Install the fuel line clip (1) to the bracket on the automatic transmission. Page 16282 Page 12069 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 8914 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 23791 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 14297 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). Page 22142 Seat Lumbar Vertical Motor - Passenger (AN3) Telescoping Actuator C1 Seat Recline Motor - Driver (AN3) Page 15756 1. Install the fuse to the holder. 2. Install the positive battery cable terminal to the fuse stud. 3. Install the generator battery jumper cable terminal (4) to the fuse stud. Notice: Refer to Fastener Notice. 4. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 N.m (80 lb in). Page 23271 Page 14357 Page 12568 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 3482 If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Memory Steer Description Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Page 19114 1 - Window Switch - Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 3 - Door Latch Assembly - Right Rear 4 - Speaker - Right Rear Door 5 - Window Motor Right Rear (A31) Page 2889 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 9362 Page 12128 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 11265 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 5829 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 22456 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Locations Seat Position Sensor: Locations SIR Component Views Driver Seat 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (AN3) Page 2197 Knock Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 5988 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 12677 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 24752 A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Page 7624 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 8903 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 11408 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 9723 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 11538 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Exhaust System - Underbody Rattle/Clunk/Rumble Noise Exhaust Pipe: All Technical Service Bulletins Exhaust System - Underbody Rattle/Clunk/Rumble Noise Bulletin No.: 07-06-05-003 Date: March 08, 2007 TECHNICAL Subject: Exhaust Pipe / Muffler Rumble, Rattle, Moan, Drone, Vibration Noise (Align Exhaust and Install New Exhaust Seals) Models: 2007 Chevrolet Silverado 1500 Series Only 2007 GMC Sierra 1500 Series Only Condition Some customers may comment on an underbody rattle/clunk/rumble noise. Cause This condition may be due to insufficient clearance between the exhaust and transmission crossmember. Correction Measure the clearance between the exhaust pipe and the transmission crossmember. If the clearance is between 15 mm-30 mm (0.59 in-1.18 in), this is not the cause of the customer's concern. Do not proceed with this bulletin. Continue to diagnose the customer's concern. If the clearance is less than 15 mm (0.59 in), realign the exhaust following steps 2-6. Disconnect the Y-pipe outlet from the exhaust muffler assembly. Loosen both the left and right exhaust manifold pipe nuts. It may be necessary to remove the right side 02 sensor to gain access to all the right side exhaust manifold nuts. The left exhaust MUST be torqued first. Tighten the left exhaust manifold pipe bolts in the sequence indicated in illustration "A" above. Tighten: Tighten the bolts to 50 N.m (37 lb ft). Monitor the clearance between the exhaust pipe and the transmission crossmember. It may be necessary to push up on the exhaust while tightening the right exhaust manifold nuts in order to achieve a minimum clearance of 15 mm (0.59 in). Page 20287 5. Apply structural adhesive epoxy, Lord Fusor(TM) 127EZ or equivalent, to fascia at mating surface. 6. Using the alignment tabs, install the sensor housing to the fascia. 7. Allow adhesive to cure according to manufacturer's directions. Page 213 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 13441 Fluid Pressure Sensor/Switch: Service and Repair Allison - Automatic Transmission Pressure Switch Manifold Replacement Removal Procedure Important: Individual pressure switches cannot be replaced. When any pressure switch needs replacing, the entire assembly must be replaced. Important: The modulated main pressure (MAIN MOD) solenoid has been removed for clarity. 1. Remove the oil pan and transmission internal oil filter. Caution: Refer to Battery Disconnect Caution. 2. Disconnect the internal wiring harness connector from the transmission fluid pressure (TFP) switch (2). 3. Remove six bolts (1). Remove the TFP switch (2). Installation Procedure Page 16105 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 23084 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 23047 Audible Warning Device Control Module: Diagrams Displays and Gages Connector End Views Chime Module (UL5) Interior - Ashtray Door Will Not Close Ash Tray: All Technical Service Bulletins Interior - Ashtray Door Will Not Close TECHNICAL Bulletin No.: 08-08-49-009 Date: April 18, 2008 Subject: IP Ashtray Door May Not Close (Replace Pivot Pins) Models: 2007-2008 Chevrolet Silverado (Except Uplevel Trim LTZ) 2007-2008 GMC Sierra (Except Uplevel Trim SLT) with Base Instrument Panel Condition Some customers may comment that the instrument panel (IP) ashtray door may not close. Cause The pivot pins may have insufficient retention, allowing the ashtray door to come off the pivot bar. Correction A new service pivot pin is now available. Install two new pivot pins (1) using the steps below. 1. Remove the ashtray door assembly from the IP. Refer to Ashtray Replacement in SI. 2. Holding the ashtray assembly in your hand, grab the pivot pin and slide the pin out from the bottom side of the ashtray T-slot (1). 3. Install the new pivot pin into the T-slot of the ashtray. 4. Slide the pin tab into the T-slot until the pin tabs lock into place. 5. Repeat Steps 2-4 for the opposite side pivot pin. 6. Install the ashtray assembly back into the IP by seating the pivot pins onto the pivot bar and closing the door. 7. Cycle the ashtray door three complete times to verify that the condition has been corrected. Parts Information Warranty Information Page 4868 1. Install the surge tank inlet hose (1) to the surge tank. 2. Position the surge tank inlet hose clamp to the surge tank. 3. Install the surge tank inlet hose to the radiator. 4. Position the surge tank inlet hose clamp to the radiator. 5. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 9733 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 12946 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 7339 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 6218 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 22103 Head Rest: Service and Repair Rear Seat Head Restraint Replacement Rear Seat Head Restraint Replacement Metal Collar Quick Connect Fitting Service Fuel Line Coupler: Service and Repair Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service Tools Required J 41769 Fuel Line Quick Disconnect Tool Removal Procedure 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). Caution: Wear safety glasses when using compressed air in order to prevent eye injury. 2. Using compressed air, blow any debris from around the fittings. 3. Using J 41769, insert the correct size tool into the female connector, then push inward to release the locking tabs. 4. Pull the fuel line connection apart. Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 5. Using a clean shop towel, wipe off the male pipe end. 6. Inspect both ends of the fuel line connections for dirt and burrs. Clean or replace the components as required. Installation Procedure Page 15652 Brake Fluid Level Sensor/Switch: Diagrams Brake Fluid Level Switch Brake Fluid Level Switch Page 2483 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 21056 Rear Door Window Regulator: Service and Repair Rear Sliding Window Regulator Replacement Rear Sliding Window Regulator Replacement Removal Procedure Important: The new rear sliding window regulator and cables are serviced as an assembly. 1. Cycle the rear sliding window to the halfway position. 2. Remove the rear lower garnish molding. Important: Use a suitable tool to lift upward on the rear sliding window stops (1) to remove. 3. Remove the rear sliding window stops (1). Page 24713 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 24645 Wiper Motor: Locations Wiper/Washer Component Views Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Washer Fluid Level Switch 7 Windshield Washer Fluid Pump 8 - Air Cleaner Box Page 6536 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 19778 Disclaimer Page 24148 Page 4656 12. Install the transmission cover. Tighten the bolts to 12 N.m (106 lb in). 13. Install the automatic transmission bolts, if equipped. 14. Install the manual transmission bolts, if equipped. Tighten the bolts to 50 N.m (37 lb ft). Page 2243 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 6952 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 2294 Page 7171 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 2179 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 8127 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 21688 1 - Door Frame 2 - Door Lock Switch - Driver 3 - Speaker - Left Front 4 - Door Latch Assembly Driver Passenger Door (AU3 -AN3/DL3) Page 16088 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 3198 Impact Sensor: Diagrams SIR Connector End Views Inflatable Restraint Front Sensor - Left (10 Series) Inflatable Restraint Front Sensor - Right (10 Series) Inflatable Restraint Front Sensor (-10 Series) Page 17000 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 1209 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Page 11364 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 12713 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 3930 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 23599 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 17260 Disclaimer Page 17020 Below the I/P 1 - I/P Trim 2 - I/P Cluster Trim 3 - Floor Panel 4 - Junction Block - Left I/P 5 - Body Control Module (BCM) 6 - Transfer Case Shift Control Module 7 - Fuse Block - I/P Page 2731 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 10942 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 2507 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 20989 Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement (SLT) Rear Side Door Trim Panel Replacement (SLT) Page 10860 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 21600 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 23879 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 21545 Page 10266 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 1626 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Page 22965 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 22510 Seat Heater: Description and Operation Heated Seats Description and Operation The driver and passenger heated seats have 2 heat zone operating modes with 3 heat level modes and will operate only while the engine is running. The heat zones are determined by which of the 2 heated seat buttons are pressed, while the heat level is determined by the number of times they are pressed. Pressing the seat cushion button 1 time will activate the seat back and cushion heater elements in the high mode. Each time the seat cushion button is pressed the seat back and cushion heat level is reduced from high to medium, low, and off. Pressing the heated seat back button 1 time will activate only the seat back heater element in the high mode. Each time the seat back button is pressed the seat back heat level is reduced from high to medium, low, and off. During heated seat operation the heat zone operating mode may be changed without affecting the current heat level mode. The heated seat switches are momentary contact switches and are inputs to the driver and passenger door switches. A ground circuit is connected to the switch assembly through the door switch, and when a heated seat switch is pressed and released a brief switch signal is supplied to the door switch. Whenever the door module receives an active heated seat switch input, the active switch signal is sent to the memory seat module as a GMLAN message. The memory seat module determines the heated seat mode based on the switch messages and sends a message to the door switch to display the heated seat indicators as necessary. The memory seat module controls the voltage supply and the ground circuits to the seat heater elements. When a heated seat function is commanded active, the seat module will switch battery voltage to the heater element supply circuits, and ground is provided through pulse width modulation (PWM) low side drive control circuits. During heated seat operation both the seat back and cushion heater elements are supplied battery voltage. The seat module grounds the appropriate control circuits for back only or back and cushion heating modes, and opens or closes the active control circuits as necessary in order to maintain the desired seat temperature. The seat module relies on 4 independent inputs from thermistors located in the seat back and seat cushion of the driver and passenger seats to control heated seat temperatures. The thermistors are 2-wire sensors supplied with a 5-volt referenced signal circuit and a low reference circuit from the seat module. Resistance through the thermistors varies with temperature causing the heated seat sensor signal circuit voltage levels to decrease as the seat back temperatures rise. Page 1102 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 17839 Page 7267 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 2763 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 16012 Fuse: Locations I/P Fuse Block Fuse Block - I/P, Label Page 17389 X500 Inline Harness Connector End Views X500 Left Front Door Harness to Body Harness (YE9 -AN3/DL3) X501 Page 4089 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 20557 Page 588 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 4988 Page 15461 Installation Procedure 1. Connect the left park brake cable (1) and the right park brake cable (2) to the equalizer bar (3) on the intermediate park brake cable. 2. Connect the front park brake cable (2) to the intermediate cable connector. 3. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling. 4. Adjust the park brake. Refer to Park Brake Adjustment (Disc Brake) Park Brake Adjustment (Drum Brake). Parking Brake Intermediate Cable Replacement (JH6, JH7) Parking Brake Intermediate Cable Replacement (JH6, JH7) Removal Procedure Page 15919 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 5344 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 11141 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 12670 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15227 Caution: Refer to Brake Dust Caution. Caution: Refer to Brake Fluid Irritant Caution. Disassembly Procedure 1. Remove the brake caliper. 2. Drain all the brake fluid from the caliper. Important: The brake calipers use phenolic pistons with stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper. 3. Secure the brake caliper in a suitable holding device. 4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge. 5. Cover the brake caliper with a shop towel. 6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper. Page 3269 Battery Current Sensor: Diagrams Battery Current Sensor (10 Series) Battery Current Sensor (10 Series) Page 4574 Step 8 - Step 13 Page 7250 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 14839 Torque Converter Clutch Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 7830 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 11824 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 5504 Water Pump: Service and Repair Water Pump Replacement (LU3) Tools Required j 41240 Fan Clutch Remover and Installer Removal Procedure 1. Remove the air cleaner outlet duct. 2. Remove the drive belt. 3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 4. Reposition the radiator outlet hose clamps at the surge tank and water pump. 5. Remove the radiator outlet hose from the surge tank. 6. Remove the radiator outlet hose from the water pump. 7. Reposition the water pump inlet hose clamps. 8. Remove the water pump inlet hose. 9. Using J 41240, hold the water pump pulley, remove the water pump pulley bolts. Page 7366 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 8614 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 11656 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 23575 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 11814 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 17505 For vehicles repaired under warranty, use the table. Disclaimer 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 5116 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 13587 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Service and Repair Power Take-Off Switch: Service and Repair Power Take-Off Switch Replacement Page 17828 Ball Joint: Specifications Ball Joint Inspection (Lower Ball Joint) The dial indicator reading should be no more than 2 mm (0.079 in). If the reading is out of specification, replace the ball joint. Ball Joint Inspection (Upper Ball Joint) Release the arm and check the dial indicator. The dial indicator reading should be no more than 2 mm (0.079 in). If the reading is too high, replace the upper control arm. Refer to Upper Control Arm Replacement. Page 12272 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 11714 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 19181 Disclaimer Page 16774 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 12581 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 12729 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 16542 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 10506 2. This step applies to Bartholomew style connector ONLY. Squeeze the plastic quick connect fitting release tabs. 3. This step applies to Release Tab style connector ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting. 4. This step applies to the Squeeze to Release style connector ONLY. Squeeze where indicated by the arrows shown above on both sides of the plastic ring surrounding the quick connect fitting. 5. This step applies to the Sliding Retainer style connector ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move try pressing the tab in from the opposite side. The tab will only move in one direction. Page 20700 Page 7620 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: All Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 11331 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 15894 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 6384 Page 16113 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 4617 3. Install the drain plug. Tighten the plug to 25 N.m (18 lb ft). 4. Lower the vehicle. 5. Fill the engine with the proper capacity and quality of engine oil. Refer to Approximate Fluid Capacities. 6. Operate the engine, check for leaks, and oil pressure. Page 12941 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 6891 View of the connector when released from the component. View of another type of Micro 64 connector. Page 16942 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11521 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 6494 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 15030 Tighten the bolt to 11 N.m (97 lb in). 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. Tighten the bolts to 11 N.m (97 lb in). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3563 6. Inspect for evidence of improper arcing. * Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. * Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. * Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). * Inspect for a broken or worn side electrode (3). * Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. * Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. * Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. * Inspect for excessive fouling. 7. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection 1. Normal operation-Brown to grayish tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: * Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion * Reduced ignition system voltage output - Weak ignition coils - Worn ignition wires - Incorrect spark plug gap * Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not affect spark intensity unless they form into a glazing over the electrode. Page 8949 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 10613 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 1802 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2796 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 172 Page 13191 Fluid - A/T: Testing and Inspection 6L50/6L80/6L90 Transmission Fluid Checking Procedure Transmission Fluid Check This procedure checks the transmission fluid level, as well as the condition of the fluid itself. Notice: Always use the proper automatic transmission fluid listed. Using incorrect automatic transmission fluid may damage the vehicle. Before checking the fluid level, perform the following: 1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then, move the shift lever back to PARK (P). 4. Allow the engine to idle 500-800 rpm for at least 1 minute. Slowly release the brake pedal. 5. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center (DIC) or a scan tool. 6. Using the TFT reading, determine and perform the appropriate check procedure. If the TFT reading is not within the required temperature ranges, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. Cold Check Procedure Important: Use this procedure only as a reference to determine if the transmission has enough fluid to be operated safely until a hot check procedure can be made. The hot check procedure is the most accurate method to check the fluid level. Perform the hot check procedure at the first opportunity. Use this cold check procedure to check fluid level when the TFT is between 80°F and 90°F (27°C and 32°C). 1. Locate the transmission dipstick at the rear of the engine compartment, on the passenger's side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe it with a clean rag or paper towel. 3. Install the dipstick by pushing it back in all the way, wait three seconds and then pull it back out again. Important: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection in this procedure. 6. If the fluid level is below the COLD check band, add only enough fluid as necessary to bring the level into the COLD band. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. 7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. 8. Perform a hot check at the first opportunity after the transmission reaches a normal operating temperature between 160°F to 200°F (71°C to 93° C). Hot Check Procedure Important: Us this procedure to check the transmission fluid level when the TFT is between 160°F and 200°F (71°C and 93°C). The hot check procedure is the most accurate method to check the fluid level. The hot check should be performed at the first opportunity in order to verify the cold check. The fluid level rises as fluid temperature increases, so it is important to ensure the transmission temperature is within range. 1. Locate the transmission dipstick at the rear of the engine compartment, on the passenger's side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe it with a clean rag or paper towel. 3. Install the dipstick by pushing it back in all the way, wait three seconds and then pull it back out again. Important: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection. 6. A safe operating fluid level is within the HOT crosshatch band on the dipstick. If the fluid level is not within the HOT band, and the TFT is between 160°F and 200°F (71°C and 93°C), add or drain fluid as necessary to bring the level into the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis. 7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. 8. If applicable and if the vehicle is equipped, reset the transmission oil life monitor only if the fluid was changed. Fluid Condition Inspection Page 20696 For vehicles repaired under warranty, use the table. Disclaimer Page 8916 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 17160 Junction Block - Right I/P X5 Page 2293 Page 16578 Install the lower B-pillar cover. Parts Information Warranty Information The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. Page 11849 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9437 Page 2813 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 1039 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 19911 Diagnostic Tips Review Table Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 22340 Rear Seat Cushion Cover and Pad Replacement (Crew Cab with A68) Rear Seat Cushion Cover and Pad Replacement (Crew Cab with A68) Page 5909 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 11171 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 3798 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the drain plug and drain the engine oil in a suitable container. 3. Remove the oil filter. 4. Inspect to ensure the engine oil filter gasket is removed. Installation Procedure 1. Lubricate the oil filter gasket with clean engine oil. Notice: Refer to Fastener Notice. 2. Install the oil filter. Tighten the filter to 30 N.m (22 lb ft). Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 24576 Washer Fluid Heater: Diagrams Wiper/Washer Connector End Views Windshield Washer Solvent Heater X1 (XA7) Windshield Washer Solvent Heater X2 (XA7) Page 16232 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 10831 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 8572 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Lighting - Turn Signals Have Increased Flash Rate Body Control Module: Customer Interest Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7071 Page 9408 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 22201 Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement Driver Seat and Passenger Seat Back Cushion Finish Panel Replacement Page 11039 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 2247 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 22635 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11948 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 8348 Body Control Module (BCM) X5 Page 10412 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 9771 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 4455 8. Remove the balance shaft retainer bolts and retainer. Important: The balance shaft and the balance shaft front bearing are serviced only as a package. Do not remove the balance shaft front bearing from the balance shaft. 9. Use a soft-faced hammer in order to remove the balance shaft from the engine block. 10. Clean and inspect the balance shaft, if necessary. Refer to Balance Shaft Cleaning and Inspection. Installation Procedure Important: The balance shaft drive and balance shaft driven gears are serviced as a set. The set includes the balance shaft driven gear bolt. 1. Apply clean engine oil to the balance shaft front bearing. 2. Using J 36996 and J 8092, install the balance shaft. Notice: Refer to Fastener Notice. 3. Install the balance shaft retainer and bolts. Tighten the bolts to 12 N.m (106 lb in). OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 21439 Instrument Panel Compartment Door Replacement (with RPO SLT) Instrument Panel Compartment Door Replacement (with RPO SLT) Page 16470 X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Page 5812 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 15870 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20768 Front Door Weatherstrip: Service and Repair Front Side Door Roof Drip Weatherstrip Replacement Front Side Door Roof Drip Weatherstrip Replacement Page 4051 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 1808 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 9614 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 9632 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 11842 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 17854 Page 15709 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Locations Sunroof / Moonroof Module: Locations Sunroof Component Views Sunroof Module 1 - Sunroof Module 2 - Left Outer Frame Panel Page 16016 Page 11986 Knock Sensor: Connector Views Engine Controls Connector End Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Page 18967 Seat Belt: Service and Repair Seat Belt Replacement - Center Rear (Extended Cab) Seat Belt Replacement - Center Rear (Extended Cab) Page 11721 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 18225 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (with RPO SLT) Page 7864 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 14910 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 12162 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Page 2780 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 2867 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 5405 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 15889 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 4913 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 6996 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 24137 Turn Signal/Malfunction Switch X3 Page 2047 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 12274 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Diagrams Automatic Volume Control: Diagrams Entertainment/Communication Connector End Views Rear Seat Audio (RSA) Controller X1 (UK6) Rear Seat Audio (RSA) Controller X2 (UK6) Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 1124 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 22335 Seat Cushion Trim Cover and Pad Replacement Seat Cushion Trim Cover and Pad Replacement Page 10930 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 17880 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Page 14790 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 6164 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 8096 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 3101 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Locations Exterior Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 8103 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Diagrams Oil Pressure Sender: Diagrams Displays and Gages Connector End Views Engine Oil Pressure (EOP) Sensor (Gas) Page 4015 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 16162 SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Sensor: Customer Interest SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 11816 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 535 Radiator Cooling Fan Motor Relay: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 12933 Vehicle Zoning Strategy Truck Zoning Page 18771 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Driver Door Page 23064 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 14291 8. Install the boot (1) and the boot clamp (2) on the tripot housing (3). 9. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise. 10. For the 2500, 3500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. 11. Position the tripot end of the wheel drive shaft assembly into the base of the J 36652-98 for the 1500 models or J 36652-1 for the 2500, 3500 models. 12. Install the top half of the J 36652-98 for the 1500 models or J 36652-1 for the 2500, 3500 models. 13. Align the boot clamp (2) and the clamp. Important: Hand tighten the bolts until the bolts are snug. 14. Insert the bolts. 15. Align the tripot boot, tripot housing, and the boot clamp. Important: Alternate between the bolts until both sides of the top half of the tool touch the bottom half. 16. Tighten each bolt 180 degrees at a time. 17. Loosen the bolts and remove the halfshaft assembly from the tool. Page 23594 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 2203 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 15414 Page 2791 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 20737 Front Door Striker: Service and Repair Door Striker Replacement (Extended Cab Upper) Door Striker Replacement (Extended Cab, Upper) Removal Procedure Important: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the upper trim door upper striker cover (2). Pullstraight downward for the trim cover to release, retained by retainer clips (1). 2. Remove the door upper striker bolts (3). 3. Remove the spacer, if equipped. 4. Remove the door upper striker (4). Installation Procedure Page 2620 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 23237 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Diagrams Shock Sensor: Diagrams Theft Deterrent System Connector End Views Shock Sensor (SPO Alarm) A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 22460 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6167 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6747 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 22406 Vehicle Zoning Strategy Truck Zoning Page 2136 2. Ensure that the fuel level sensor retainers (2) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (1). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 12885 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 13580 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 7764 Page 15338 Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 23111 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 17134 Page 1043 Page 11418 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11781 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16951 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 16226 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 6415 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 549 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. JX200 - JX299 Branching Point: Diagrams JX200 - JX299 JX221 Splice Pack Connector End Views JX221 JX223 Splice Pack Connector End Views JX223 (-Y91 +U2K/UK6/UE1) Page 10590 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 13018 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 19666 Disclaimer Page 9032 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 9241 Page 5443 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6800 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 5320 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 15244 Page 19893 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 6445 Page 23394 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 16104 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9475 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 2270 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 8136 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 23106 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 3969 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 7291 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 12819 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Interior - Front Seat Cushion Cover Becomes Detached Seat Cover: All Technical Service Bulletins Interior - Front Seat Cushion Cover Becomes Detached TECHNICAL Bulletin No.: 08-08-50-001D Date: April 06, 2011 Subject: Front Seat Cushion Cover Becomes Detached (Add Push Pin Fasteners to J-Retainer) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL with Front Seat RPO Codes AN3, A95, AE7 or AZ3 Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-50-001C (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger front seat cushion cover is coming detached from the seat frame along the front edge, or that the seat cushion foam has become exposed at the front corner(s) of the seat. Correction To improve the retention of the front seat cushion cover to the seat frame, modify the cover J-retainer and add two push pin retainers, GM P/N 10121502, to securely attach the J-retainer. Follow the procedure below: Important A number of the following graphics show the seat assembly removed from the vehicle. This is for illustration purposes only. Do not remove the seat from the vehicle for this repair. Page 10124 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Circuit/System Verification Important: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. Ignition ON, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. ‹› If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 1. Ignition OFF, all accessories OFF, install the CH-48027. Refer to Fuel Pressure Gage Installation and Removal. See: Fuel Pressure Gage Installation and Removal 2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Important: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Restricted or plugged fuel filter * Restricted or plugged strainer * Stuck or binding fuel level float * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 5719 Auxiliary Body Control Module (XBCM) X2 (Export) Page 15194 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (JD9, JF3, JF7) Master Cylinder Replacement (JH6, JH7) * Front Brake Hose Replacement (JD9, JF3, JF7) Front Brake Hose Replacement (JH6, JH7) * Rear Brake Hose Replacement (Caliper - JD9) Rear Brake Hose Replacement (Caliper - JH6, JH7) Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4) Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) Rear Brake Hose Replacement (Frame to Axle JH6, JH7) * Front Brake Caliper Replacement (JD9, JF3, JF7) Front Brake Caliper Replacement (JH6, JH7) * Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JH6, JH7) * Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Brake Pressure Modulator Valve Replacement (JH6, JH7) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (JD9, JF3, JF7) Master Cylinder Replacement (JH6, JH7) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (JD9, JF3, JF7) Master Cylinder Reservoir Replacement (JH6, JH7). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (JD9, JF3, JF7) Front Brake Hose Replacement (JH6, JH7) * Rear Brake Hose Replacement (Caliper - JD9) Rear Brake Hose Replacement (Caliper - JH6, JH7) Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4) Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) Rear Brake Hose Replacement (Frame to Axle JH6, JH7) * Front Brake Caliper Overhaul (JH6, JH7) or Front Brake Caliper Replacement (JD9, JF3, JF7) Front Brake Caliper Replacement (JH6, JH7) * Rear Brake Caliper Overhaul (JH6, JH7) or Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JH6, JH7) * Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Brake Pressure Modulator Valve Replacement (JH6, JH7) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, Page 24156 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 9072 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 13832 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 23006 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Fluid Pump: Customer Interest A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 10632 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Cable: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the clips on the cable from the floor panel reinforcement. 4. Ensure the transmission manual shaft is positioned in mechanical park. 5. Remove the retainer that secures the cable to the bracket. 6. Remove the cable clip on the transfer case, if equipped. 7. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). 8. Depress the tangs and remove the cable from the bracket. 9. Lower the vehicle. 10. Ensure that the steering column shift lever is still in the park position. 11. Remove the drivers seat. 12. Pull back the carpet and insulation around the driver's area. 13. Remove the instrument panel knee bolster. Page 19017 Seat Belt Buckle: Service and Repair Rear Seat Center Belt Buckle Replacement (Crew Cab) Rear Seat Center Belt Buckle Replacement (Crew Cab) Service and Repair Cabin Air Filter: Service and Repair This vehicle is not equipped with a factory installed passenger compartment air filter. Page 5138 View of the connector when released from the component. View of another type of Micro 64 connector. Page 14815 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (367A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Page 18224 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Instrument Panel Outer Air Outlet Replacement - Left Side (without RPO SLT) Page 2357 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 9190 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 21827 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 6369 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Diagrams Hazard Warning Switch: Diagrams Power and Grounding Connector End Views Roof Beacon Relay (TRW) Page 2281 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 16038 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 12711 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 5106 Page 4737 11. Remove the balance shaft drive gear. 12. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o'clock position. 13. Position the balance shaft drive gear onto the engine camshaft. 14. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned. 15. Install the timing chain and the camshaft sprocket. 16. Install the valve lifter pushrod guide. 17. Install the A/C condenser. 18. Install the radiator. Page 12969 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 1083 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 5030 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 11146 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 15028 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: * M6 X 1.0 X 65.0 (1) * M6 X 1.0 X 54.4 (2) * M6 X 1.0 X 47.5 (3) * M6 X 1.0 X 35.0 (4) * M8 X 1.0 X 20.0 (5) * M6 X 1.0 X 12.0 (6) * M6 X 1.0 X 18.0 (7) Page 11277 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 6334 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 14245 Axle Bearing: Service and Repair Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Special Tools ^ J 2222-C Wheel Bearing Nut Wrench ^ J 8092 Universal Driver Handle - 3/4 x 10 inch ^ J 24426 Outer Wheel Bearing Race Installer ^ J 24427 Inner Wheel Bearing Race Installer ^ J 44419 Hub Bearing Installer ^ J 44420 Differential Bearing Installer Removal Procedure Note: ^ The wheel speed sensor ring is NOT serviced separately. The hub and wheel speed senor ring are serviced as an assembly. ^ The rear axle hub seal must be replaced anytime the rear axle hub assembly is removed from the axle housing. ^ The wheel studs are serviced separately from the rear axle hub. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. Note: In the following service procedure, it is not necessary to remove the brake caliper from the bracket. 3. Remove the brake caliper bracket. 4. Remove the rear axle shaft. 5. Remove the rear axle nut retaining ring. Page 7130 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 23191 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 1839 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 16004 Fuse Block - I/P, Device Usage Page 4854 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: - Give freezing protection down to -34°F (-37°C). - Give boiling protection up to 265°F (129°C). - Protect against rust and corrosion. - Help keep the proper engine temperature. - Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Page 13508 2. Connect the electrical connector. 3. Adjust the shift lock control actuator (with the shift lever clevis in the neutral position) in the following way: 1. Pull out the tab (1) on the adjuster block side (2) of the shift lock control actuator. 2. Press on the adjuster block (2) to compress the internal adjuster spring which disengages the adjuster teeth. Slide the adjuster block (2) as far away from the actuator as possible. 3. Lock the adjuster block (2) in place by pushing in on the tab (1). 4. Inspect the shift lock control actuator for the following items: 1. The shift lock control actuator must lock the shift lever clevis when the shift lever clevis is put into the park position. 2. Depress the brake pedal to move the shift lever out of the park position. 3. The actuator will be energized. 4. Readjust the shift lock control actuator if needed. 5. Install the knee bolster. 6. Enable the SIR system. Page 9688 Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (2). Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S pigtail electrical connector (5) to the engine wiring harness electrical connector (4). 4. Install the CPA retainer. 5. Lower the vehicle. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 3033 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Ring Gear: Service and Repair Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Tools Required * J 22536 Pinion Driver, 8.6 inch, 9.5/9.5LD inch axles * J 44421 Pinion Remover, 11.5 inch axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion yoke and the oil seal. 4. Install the J 22536, 8.6 inch or 9.5/9.5LD inch axle, or the J 44421, 11.5 inch axle as shown. Ensure that the J 22536 or the J 44421 is firmly seated on the pinion. 5. Drive the pinion out using the J 22536 or the J 44421 and a hammer. Strike the J 22536 or the J 44421 slowly. Do not let the pinion fall out of the rear axle housing. 6. Remove the collapsible spacer from the pinion. Discard the spacer. 7. Remove the pinion bearings and the cups. Important: The ring gear bolts on the 8.6 inch and the 9.5/9.5LF inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. 8. Remove the gear bolts. Discard the bolts. Notice: Refer to Ring Gear Removal Notice. 9. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Page 13521 Page 8901 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 16943 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 14761 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Front Suspension Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Suspension Shock Absorber Shock Absorber Disposal Shock Absorber Disposal Caution: Gas charged shock absorbers contain high pressure gas. Do not remove the snap ring from inside the top of the tube. If the snap ring is removed, the contents of the shock absorber will come out with extreme force which may result in personal injury. Caution: To prevent personal injury, wear safety glasses when centerpunching and drilling the shock absorber. Use care not to puncture the shock absorber tube with the centerpunch. 1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch. 2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended. 3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 4. Make an indentation in the middle (2) of the tube (3) with a centerpunch. 5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil. 6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber. Shock Absorber and Spring Assembly Replacement Shock Absorber and Spring Assembly Replacement Page 9300 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 8543 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 3989 Fuse: Application and ID Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 10886 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Notice: Refer to Fastener Notice. 2. Install the accelerator pedal bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: Page 6803 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 4395 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 20609 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 6031 Page 82 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 11843 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 11828 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 14574 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten the bolts in the sequence shown to 11 N.m (97 lb in). 15. Ensure that the manual detent spring is aligned properly with the detent lever. Page 13107 Disclaimer Page 11650 Page 24183 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 9152 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 24309 Power Window Switch: Diagrams Window Systems Connector End Views Window Switch - Driver X1 (A31 -AN3/DL3) Window Switch - Driver X2 (A31 -AN3/DL3) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 4243 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 2921 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 1991 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 9455 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 14573 7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). 8. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. Important: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified. 9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: * M6 X 1.0 X 65.0 (1) * M6 X 1.0 X 54.4 (2) * M6 X 1.0 X 47.5 (3) * M6 X 1.0 X 35.0 (4) * M8 X 1.0 X 20.0 (5) * M6 X 1.0 X 12.0 (6) * M6 X 1.0 X 18.0 (7) Page 7925 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5832 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 1570 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement Page 3766 Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the bottom pan for excessive metal particles or other debris. A small amount of "friction" material in the bottom pan is a "normal" condition. If large pieces and/or metal particles are noted in the fluid or bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission. Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 5194 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 24164 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 21433 Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Page 6995 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 15510 Page 6981 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 6548 Page 9871 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 1163 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 1403 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 24282 Power Window Switch: Service and Repair Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Interior - Front Power Seat Adjust/Memory Inoperative Power Seat Switch: Customer Interest Interior - Front Power Seat Adjust/Memory Inoperative Bulletin No.: 06-08-50-012 Date: October 06, 2006 TECHNICAL Subject: Front Driver or Passenger Power Seat Adjust Functions Inoperative and/or Driver Seat Memory Inoperative (Check Power Seat Switch Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (New Style), Suburban, Tahoe 2007 GMC Sierra (New Style), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the front driver or passenger power seat adjust functions are inoperative. They may also comment that the driver seat memory is inoperative. Cause The cause of this condition may be due to the power seat switch connector not being fully seated. Correction Remove the front seat cushion outer trim panel following the replacement procedure in SI. Verify that the power seat switch connector is fully seated. Reseat the connector and test the seat functions. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9493 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 16086 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 18604 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Interior HVAC Module 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 24233 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Service and Repair Coolant Line/Hose: Service and Repair Water Outlet Tube Replacement (LU3) Removal Procedure 1. Remove the air cleaner outlet resonator duct. 2. Remove the radiator inlet hose. 3. Remove the turbocharger coolant bypass valve. 4. Remove the water outlet bolts. 5. Remove the water outlet. 6. Remove and discard the gasket. Installation Procedure 1. Install a NEW gasket to the water outlet. Page 8436 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 17710 Page 15860 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 15465 7. Release the park brake cable from the rear axle bracket by compressing the locking tabs and pulling the park brake cable conduit (1) rearward. 8. Disconnect the park brake cable eye (2) from the park brake actuator lever. 9. Remove the park brake cable assembly from the vehicle. Installation Procedure 1. Connect the left park brake cable eye (2) to the park brake actuator lever. 2. Install the park brake cable to the rear axle bracket by pulling the cable conduit (1) rearward and inserting the cable conduit into the rear axle bracket. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Page 19912 Page 2655 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10444 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 12991 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 4154 Page 9157 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 16732 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 9589 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 24211 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6324 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16598 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 2963 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 10750 Fuel Tank Unit: Service and Repair Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 24644 Disclaimer Headlining Trim Panel Replacement (Crew Cab) Headliner: Service and Repair Headlining Trim Panel Replacement (Crew Cab) Headlining Trim Panel Replacement (Crew Cab) Page 8262 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2978 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 20050 Speaker: Service and Repair Radio Front Speaker Grille Replacement Radio Front Speaker Grille Replacement Page 7863 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 19816 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Page 9071 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 2702 Page 11230 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Door Striker Replacement (Crew Cab) Front Door Striker: Service and Repair Door Striker Replacement (Crew Cab) Door Striker Replacement (Crew Cab) Removal Procedure Important: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the lower striker bolt. 2. Loosen the upper striker bolt enough in order to rotate the striker and the spacer, if equipped, away from the lower bolt hole. 3. Install the lower striker bolt. Tighten the lower striker bolt sufficiently in order to hold the striker backing plate in place. 4. Remove the upper striker bolt (1). 5. Remove the spacer, if equipped. 6. Remove the striker (2). Installation Procedure Page 17164 Junction Block - Rear Lamps X3 Junction Block - Rear Lamps X4 Page 15178 Page 24750 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 15220 Page 13353 Transmission Control Module (TCM), Engine Side Page 12655 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 14873 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 4378 Wheel Hub: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Page 3271 1. Squeeze the negative battery cable branches together. Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 2. Slide the NEW battery current sensor (2) up onto the negative battery cable to the location previously marked during removal. 3. Wrap electrical tape around the battery current sensor leg in order to secure the sensor to the negative battery cable. 4. Install the negative battery cable clips (1) to the cable to the locations previously marked during removal. 5. Install the negative battery cable. Page 3982 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 5296 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 18098 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 15219 Rear Brake Caliper Bracket Replacement (JH6, JH7) Rear Brake Caliper Bracket Replacement (JH6, JH7) Locations Fuel Pressure Sensor/Switch: Locations Engine Controls Component Views Near the Fuel Tank 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (- Diesel) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Line Pressure Sensor (-LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly - Front (Gas) Page 3951 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 3708 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (Non HP2) Evaporator Tube Replacement (Non HP2) Tools Required J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the upper radiator air baffle and deflector. 3. Remove the air cleaner assembly. 4. Remove the surge tank hold down nut and bolt and position aside. Important: Do not open cooling system. 5. Remove the evaporator tube nut from the evaporator. 6. Disconnect the evaporator tube from the evaporator. 7. Remove the evaporator tube nut from the auxiliary A/C tube, if equipped. 8. Disconnect the evaporator tube from the auxiliary A/C tube, if equipped. 9. Remove the evaporator tube nut from the condenser. 10. Disconnect the evaporator tube from the condenser. 11. Remove the evaporator tube from the vehicle. 12. Discard all of the used sealing washers. Cap all of the open connections. Installation Procedure 1. Connect the evaporator tube to the condenser using new sealing washers. Notice: Refer to Fastener Notice. Page 3288 Steering Angle Sensor: Removal and Replacement Steering Wheel Position Sensor Replacement Page 6592 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 17138 Part 1 Electrical Center Identification Views Junction Block - Left I/P, Top View Page 7974 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 10442 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 22327 Front Seat Center Cushion Replacement Front Seat Center Cushion Replacement Page 10960 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 12489 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 14334 14. Remove the retaining ring from the wheel hub. 15. Remove the outer hub bearing and bearing cup using the J 24426 (2) and the J 8092 (1). Installation Procedure 1. Lubricate the following with a light coat of high melting point EP bearing lubricant: * The outer wheel bearing * The inner wheel bearing * The outer wheel bearing cup * The inner wheel bearing cup * The axle housing 2. Install the outer bearing into the wheel hub. Page 1150 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 6002 and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 6. Connect a test lamp between the relay coil B+ and the relay coil control circuit. 7. Ignition ON, command the powertrain relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the relay coil control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the relay coil control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 8. Connect a 20A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 9. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 10. If all circuits test normal, test or replace the relay. Component Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Test for 65-110 ohms of resistance between terminals 85 and 86 of the relay. ‹› If the resistance is not within the specified range, replace the relay. 3. Test for infinite resistance between following terminals: * Terminal 30 and 86 * Terminal 30 and 87 * Terminal 30 and 85 * Terminal 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 20A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm of resistance between terminals 30 and 87. ‹› If greater than the specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Relay Replacement (Within an Electrical Center) Relay Replacement (Attached to Wire Harness) * Underhood Electrical Center or Junction Block Replacement * Refer to Programming and Relearning for setup and programming. See: Testing and Inspection/Programming and Relearning HVAC - Automatic Blower Motor: Diagrams HVAC - Automatic HVAC Connector End Views Blower Motor Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 12197 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. A/T - Valve Body Reconditioning Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Bulletin No.: 07-07-30-024 Date: September 27, 2007 INFORMATION Subject: Information on 4L60-E M30 Rear Wheel Drive Automatic Transmission Valve Body Reconditioning, DTC P0741, P0756, P0894, Harsh 1-2 Shift Models The following new service information outlined in this bulletin will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. This service bulletin will also provide additional service information documents that are related to the 4L60-E transmission. Related Service Documents DTC P0741 - Torque Converter Clutch (TCC) System - Stuck Off. Refer to Service Bulletin 04-07-30-041. DTC P0756 - 2-3 Shift Solenoid Valve Performance - No First or Second Gear. Refer to Service Bulletin 01-07-30-036F. DTC P0894 - Transmission Component Slipping. Refer to Service Bulletin 06-07-30-007. Harsh 1-2 Shift. Refer to Bulletin PIP3170E. If valve body cleaning is not required, Do Not disassemble the bores unless it is necessary to verify movement of valves. Page 6252 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Caution Caution: Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 6123 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Body - Roof Panel Flutters/Rattle Noise When Doors Close Headliner: All Technical Service Bulletins Body - Roof Panel Flutters/Rattle Noise When Doors Close TECHNICAL Bulletin No.: 08-08-67-016F Date: January 24, 2011 Subject: Roof Panel Flutters or Rattle Noise from Roof or Headliner when Closing Doors (Apply Foam) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Models Only), Suburban, Tahoe 2010-2011 Chevrolet Equinox 2007-2009 GMC Sierra (Crew Cab Models Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2010-2011 GMC Terrain Supercede: This bulletin is being revised to add the 2011 model year to Equinox/Terrain models. Please discard Corporate Bulletin Number 08-08-67-016E (Section 08 - Body and Accessories). Condition Some customers may comment that the roof panel flutters and/or there is a rattle noise from the roof or headliner when closing one of the side doors or the liftgate. Cause This may be caused by the excessive motion of the roof panel. On initial inspection, you may notice that the roof panel expansion adhesive material has separated between the roof and the roof bow. The concern is seen mostly on the first cross bow. Correction Lower the headliner assembly (it is not usually necessary to remove the headliner from the vehicle) to gain access to the roof bows. Refer to Headlining Trim Panel Replacement in SI. Remove any loose foam from the roof bow or bows. Apply Fusor super flexible anti-flutter foam-fast set, Fusor P/N 121/124, or equivalent, in a continuous bead the entire length between the roof bow reinforcement and the roof outer panel. Reinstall the headliner. Refer to Headlining Trim Panel Replacement in SI. Parts Information Contact Lord Fusor at 1-877-275-5673 or on the Web at www.lord.com. Warranty Information For vehicles repaired under warranty, use the table. Page 2060 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 5129 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 10585 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 9205 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Accessories - Pick Up Box Accessory Mounting Information Truck Bed Storage Compartment: Technical Service Bulletins Accessories - Pick Up Box Accessory Mounting Information INFORMATION Bulletin No.: 09-08-66-011A Date: October 04, 2010 Subject: Information on Mounting Points for Pickup Box Accessories Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-011 (08 - Body and Accessories). The pickup box was designed for the use of add-on equipment. However there are specific mounting points that must be used along with weight restrictions, refer to the following: Chart 1 - Weight Restrictions for Pickup Box Add-Ons. Structural members have been added to provide load paths directly to the platform cross-sills and into the vehicle frame. Aftermarket accessories should take advantage of these intended load paths as detailed below in Figures 1-4. Depending on the accessory design, it may be necessary to add some form of a spacer under the accessories at the structural hard points to take up any gap. Do not use the GM Cargo Management Option mounting points for attaching anything other than the GM Cargo Management system as referenced in Figure 5. Figure 1 - Side View - Structural Members Figure 2 - Top View - Structural Members Figure 3 - Top View - Front Structure Page 4136 Page 10940 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 13689 Shift Cable: Service and Repair Allison - Automatic Transmission Range Selector Lever Cable Replacement Removal Procedure 1. Position the steering column shift lever to the park position. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the range selector cable heat shield bolts. 4. Remove the range selector cable heat shield. 5. Ensure the transmission manual shaft is positioned in mechanical park. 6. Remove the range selector cable end from the transmission range selector lever stud. 7. Remove the retainer securing the range selector cable to the bracket. Page 3859 Fuse: Locations Left I/P Junction Block Junction Block - Left I/P, Label Junction Block - Left I/P, Device Usage Page 23912 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 8245 Information Bus: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 16168 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 977 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 9438 Vehicle Zoning Strategy Truck Zoning Page 12853 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 23363 Page 20656 Driver/Vehicle Information Display: Diagrams Displays and Gages Connector End Views Displays and Gages Connector End Views Driver Information Center (DIC) Switch 4L60-E/4L65-E/4L70-E - Automatic Transmission Control Module: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (TCM) 1 - Transmission Control Module (TCM) Page 10839 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Brakes - Aftermarket Trailer Brake Controllers Trailer Brake Control Module: All Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 12110 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 11262 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 8884 Page 21799 Service and Repair Cabin Ventilation Duct: Service and Repair Air Inlet Assembly Replacement Page 11495 5. Position the spark plug wires to the ignition coil. 6. Connect the spark plug wires (1, 2) to the ignition coil as noted during removal. 7. Place the engine wiring harness rear bracket onto the upper intake manifold and install the bolts. Tighten the bolts to 10 N.m (89 lb in). Page 16980 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 424 Radiator Cooling Fan Control Module: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 9652 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 16729 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 17331 Inline Harness Connector End Views X321 Body Harness to Headliner Harness (A48) X322 Inline Harness Connector End Views X322 Body Harness to UPA Jumper Harness (UD7) Page 8345 Body Control Module (BCM) X2 Page 14920 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 8920 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 13515 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 2656 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 23605 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13559 View of the connector when released from the component. View of another type of Micro 64 connector. Page 18494 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement (Non HP2) Evaporator Tube Replacement (Non HP2) Tools Required J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the upper radiator air baffle and deflector. 3. Remove the air cleaner assembly. 4. Remove the surge tank hold down nut and bolt and position aside. Important: Do not open cooling system. 5. Remove the evaporator tube nut from the evaporator. 6. Disconnect the evaporator tube from the evaporator. 7. Remove the evaporator tube nut from the auxiliary A/C tube, if equipped. 8. Disconnect the evaporator tube from the auxiliary A/C tube, if equipped. 9. Remove the evaporator tube nut from the condenser. 10. Disconnect the evaporator tube from the condenser. 11. Remove the evaporator tube from the vehicle. 12. Discard all of the used sealing washers. Cap all of the open connections. Installation Procedure 1. Connect the evaporator tube to the condenser using new sealing washers. Notice: Refer to Fastener Notice. Page 3096 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 13523 Page 3699 Installation Procedure 1. Install the inlet heater hose. 2. Install the inlet heater hose to the water pump. 3. Connect the heater hose to the heater core. Important: Firmly push the quick connect onto the heater core pipe until you hear an audible click. 4. Install the heater and surge tank hoses to the mounting clip. 5. Install the air intake tube. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Locations Hood Sensor/Switch (For Alarm): Locations Immobilizer Component Views Near the Hood Latch 1 - Upper Tie Bar 2 - Hood Ajar Switch (AP3/AP8) 3 - Ambient Air Temperature Sensor - ISRVM Page 24437 8. Remove the pulley (1) from the frame. 1. Lift the end of the tabs (2) out of the window frame (3). 2. Turn upward to release the pulley (1) from the frame (3). 9. Remove the cable ends (1) from the window guide (2) at each end of the window. Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 17233 The concern must be current before diagnosis can be performed. Review and print the following SI documents - Electrical Center Identification Views, for use during diagnosis: - Junction Block - Right I/P, Top View - Junction Block - Right I/P X4 - Junction Block - Right I/P X5 Locate the Junction Block - Right Side IP on the vehicle. For the appropriate actuator, measure the following signals for voltage/resistance from the BACK of the X4 or X5 connector and record the following: DO NOT unplug the X4/X5 connector. Turn Ignition On, A/C Blower Full, if possible - mode on "panel" and Temp to "cold." Once the fault is removed, the actuator will stay in default position until commanded to a new position. Change commanded position regularly to see if the issue is still current. Continue to monitor door positions (feedback) on Tech2 to see if it changes during circuit testing. - Ignition Voltage - 12V - Door Control Signal - 2.5V when stationary, OV when commanded toward "cold" or "panel", 5V when commanded toward "hot" or "defrost" - Low Reference - less than 40 ohm with ignition on. Less than 10 ohm with ignition off - Door Position Signal - measure voltage - 5 Volt Reference - 5V If any signals do not display the correct value or if the issue is corrected during testing, pull the connector and check the terminal for poor tension (use the appropriate terminal tool). Replace or repair the terminal if poor tension is found. If all signals are correct at RH BEC, reconfirm the customer's comments. If the condition is not present, no further repairs are necessary. If the condition is still present, recheck the actuator connector 5 volt reference circuit, pin drag test and repair connector/pin as necessary. Warranty Information For vehicles repaired under Enqineerinq direction, use the table. Page 9125 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 2348 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Check Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 6677 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 12116 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 2850 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8965 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 6709 Page 16413 X211 Instrument Panel Harness (Y91) Or I/P Extension Harness (-Y91) To Console Harness (Y91/UQA/D07) (Pin C7 To D8) X212 Inline Harness Connector End Views X212 Instrument Panel Harness to Instrument Panel Extension Harness (-Y91) Page 2360 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 1382 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Front (with DL8 and without SLT) Door Lock Switch Replacement - Front (with DL8 and without SLT) Page 24733 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 10991 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 13638 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. Tighten the bolt to 12 N.m (108 lb in). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Page 18205 Air Temperature Actuator Replacement - Left Side Air Temperature Actuator Replacement - Left Side Page 9492 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4654 Important: Always install a NEW oil pan gasket. The oil pan gasket and oil pan must be installed and the fasteners tightened while the adhesive is still wet to the touch. 3. Install a NEW oil pan gasket into the groove in the oil pan. Important: The oil pan alignment must always be flush or forward no more than 0.3 mm (0.011 in) from the rear face of the engine block. 4. Install the oil pan. Press the oil pan gasket into the grooves of the engine front cover and crankshaft rear oil seal housing. 5. Slide the oil pan back against a suitable straight edge. 6. Install the oil pan bolts and nuts until snug. 7. Measure the oil pan-to-transmission housing clearance using a feeler gage and a straight edge. Use the feeler gage to check the clearance at the oil pan-to-transmission housing measurement points (1). If the clearance exceeds 0.3 mm (0.011 Page 14743 View of the connector when released from the component. View of another type of Micro 64 connector. Page 18237 Ambient Temperature Sensor / Switch HVAC: Diagrams HVAC Connector End Views Ambient Air Temperature Sensor - HVAC Page 7022 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 7754 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Allison - Automatic Transmission Control Module: Service and Repair Allison - Automatic Transmission Transmission Control Module Replacement Page 4720 5. Using the J 42073, install the valve stem oil seal onto the valve guide. 1. Tap the valve stem oil seal onto the valve guide until the J 42073 bottoms against the valve spring seat. 2. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed against the valve guide. There should be a 1-2 mm (0.03937-0.07874 in) gap between the bottom edge of the valve stem oil seal and the valve guide. 6. Install the valve spring (3). 7. Install the valve spring cap (2) onto the valve spring (3), over the valve stem. Caution: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. 8. Use the J 5892-D in order to compress the valve spring. Hook the slotted end of J 5892-D under the washer on the valve rocker arm bolt. 9. Apply steady pressure on the valve spring cap until the valve keys are accessible. Page 2065 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 12800 Page 3396 Transmission Position Switch/Sensor: Service and Repair Allison - Automatic Transmission Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Page 7284 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 8452 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 2811 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 9151 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 17205 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 18037 2. Rotate the hoist shaft counterclockwise in order to lower the spare tire to the ground. Continue to rotate the shaft until the spare tire can be pulled out from under the vehicle and removed. If the spare tire does not lower to the ground, the secondary latch is engaged causing the tire not to lower. 3. If the secondary latch is engaged and the cable end is visible, perform the following procedure: 1. Tighten the cable by rotating the hoist shaft clockwise until you hear 2 clicks or feel it skip twice. You cannot overtighten the cable. 2. Loosen the cable by rotating the hoist shaft counterclockwise 3 or 4 turns. 3. If the spare tire can be lowered, repeat steps 1 and 2 to see if the spare tire can be removed. 4. If the spare tire cannot be lowered, rotate the hoist shaft counterclockwise until approximately 15 cm (6 in) of cable is exposed. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Place a transmission jack, or equivalent, under the spare tire. 7. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 8. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 9. Lower the tire. If the spare tire is hanging by the cable, rotate the hoist shaft counterclockwise until the tire is low enough to remove. 4. If the secondary latch is engaged and the cable end is NOT visible, perform the following procedure: 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a transmission jack, or equivalent, under the spare tire. 3. Position the center of the transmission jack under the secondary latch release button at the center of the spare tire. Arrange the arms of the transmission jack so they will support the tire after it has been released. 4. Raise the jack until the spare tire stops moving upward and is firmly held in place, releasing the secondary latch. 5. Lower the tire and remove it from the jack. 5. Raise and support the vehicle if it is not already raised. Refer to Vehicle Lifting. 6. Depress the tabs, remove the guide shaft from the hoist collar, and slide the shaft toward the bumper. 7. Remove the collar from the hoist 8. Remove the bolt. 9. Remove the hoist from the bracket. Page 8460 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 915 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 6163 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 17121 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 10953 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4L60-E/4L65-E/4L70-E - Automatic Transmission Clutch Control Solenoid Valve: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 13403 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Page 24702 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Fluid Pump: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 22917 Vehicle Zoning Strategy Truck Zoning Diagrams Fuel Gauge Sender: Diagrams Displays and Gages Connector End Views Fuel Pump and Sender Assembly - Front (Gas) Fuel Pump and Sender Assembly - Rear (Gas +LY6) Page 13542 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 22200 Front Seat Back Frame Replacement Front Seat Back Frame Replacement Page 4270 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16127 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 9397 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 2236 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 17354 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) to Headliner Harness (UE1/U3U/UVB) Page 18749 Page 6193 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 7172 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Locations Turn Signal Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 8896 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 8497 5. Remove the knock sensor bolt and sensor. Installation Procedure Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). Page 11197 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 9052 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 10067 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 22418 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 18048 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11643 Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 19393 Driver/Vehicle Information Display: Description and Operation Driver Information Center (DIC) Description and Operation The driver information center (DIC) displays the DIC WOW for 5 seconds when it first powers up. If enabled through Personalization, the DIC then returns to the last display status before no power condition. There are 4 switch functions for the DIC. * Personalization * Set/Reset * Trip/Fuel * Vehicle Info Trip/Fuel The Trip/Fuel switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Trip/Fuel switch * Accell Rate * Average Fuel Economy (AFE) * Average Vehicle Speed (AVE) * Fuel Range * Fuel Used * Instantaneous Fuel Economy (IFE)/ Displacement on Demand (DOD) * Maximum Speed * Odometer * Trans Temp * Trip A * Trip B * Trip Time Vehicle Info The Vehicle Info switch is used to navigate between vehicle information parameters. Cycle through the following vehicle parameters by successive pressing of the Vehicle Info switch. * Blank Display * English/Metric Units * Key Fob Programming Menu * Left Front Tire Pressure * Left Rear Tire Pressure * Oil Life Index (OLI) * Right Front Tire Pressure * Right Rear Tire Pressure * Tire Programming Menu Personalization The Personalization switch is used to set personalization features for both the vehicle and the driver. Many of the parameters in the Trip/Fuel menu and the Vehicle Info menu can be programmed through the Personalization switch. In addition to the parameters in the Trip/Fuel and Vehicle Info menus, the following features can also be programmed. * Approach Lighting * Automatic Door Lock * Automatic Door Unlock * Chime Volume * Delayed Door Lock * Display Language * Easy Exit Seat * Exit Lighting * Memory Seat Recall * Remote Door Lock * Remote Door Unlock * Remote Start Accessories - Tonneau Cover Handle Separates from Latch Truck Bed Cover Latch: All Technical Service Bulletins Accessories - Tonneau Cover Handle Separates from Latch Bulletin No.: 07-08-66-008 Date: November 06, 2007 TECHNICAL Subject: GM Accessory Soft Tonneau Cover Pull Strap Handle Separates from Latch (Replace Latch Assembly) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra, Sierra Denali Condition Some customers may comment that the front and/or rear tonneau cover pull strap handle separates from the tonneau cover latch. This condition typically occurs on the rear pull strap latch. Cause This condition may be caused by a weak slide eyelet (1) on the pull strap latch. Correction Replace the front and rear pull strap latches with the new design latches following the steps below. Open the tailgate. Release the left rear tonneau cover latch by using a screwdriver to slide the broken eyelet on the latch to the right. Flip the rear of the tonneau cover up. Remove the left rear plastic rail end cover from the rear tonneau cover rail. Page 11887 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 5326 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 4024 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 10594 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 12398 Transmission Speed Sensor: Locations Power Take-Off Power Take-Off (PTO) Component Views Front Frame Rail 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor 4 - Automatic Transmission Input Shaft Speed (AT ISS) Sensor 5 - Automatic Transmission 6 - Vehicle Speed Sensor (VSS) 7 - X124 8 - Power Take Off (PTO) Module 9 - X175 Page 7812 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 23564 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 23371 Page 23474 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 11798 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 9932 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 5240 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Page 6107 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Service and Repair Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Housing Replacement Removal Procedure Important: Do not remove the crankshaft rear oil seal housing if only replacing the crankshaft rear oil seal. 1. Remove the oil pan. 2. Remove the engine flywheel. 3. Remove the housing bolts and nut. 4. Remove the housing. 5. Remove and discard the housing gasket. 6. Clean all the sealing surfaces. 7. Inspect and replace the housing for warping, cracks, wear, or damage. Installation Procedure Page 7235 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 9485 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 18526 Low Pressure Sensor / Switch: Diagrams HVAC - Manual HVAC Connector End Views A/C Low Pressure Switch (C67) Reverse Lockout Solenoid Page 7885 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Caution Caution: Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 3155 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Drivetrain - Whine Type Noise From Vehicle rear Drive/Propeller Shaft: Customer Interest Drivetrain - Whine Type Noise From Vehicle rear Bulletin No.: 07-04-17-002 Date: October 25, 2007 TECHNICAL Subject: Whine Type Noise Coming from Rear of Vehicle (Diagnose and Replace Rear Propeller Shaft) Models: 2007-2008 Chevrolet Silverado Crew Cab, Ext Cab Standard (Regular) Box (1500 Series) (2WD Only) 2007-2008 Chevrolet Tahoe (2WD Only) with 4L60-E Automatic Transmission (RPO M30) (EXCEPT Police Package (RPO PPV)) 2007-2008 GMC Sierra Crew Cab, Ext Cab Standard (Regular) Box (1500 Series) (2WD Only) 2007-2008 GMC Yukon (2WD Only) with 4L60-E Automatic Transmission (RPO M30) Condition Some customers may comment on a slight whine noise coming from the rear of the vehicle at certain speeds, typically between 72-96 km/h (45-60 mph). Cause Rear axle "Inherent" ring and pinion gear whine. All gear driven units, such as automotive rear axles, produce some level of noise that cannot be eliminated with conventional adjustments and repairs. "Inherent" axle noise can be described as a slight noise heard only at a certain speed (typically between 72-96 km/h (45-60 mph) on most General Motors(R) trucks). The presence of this noise is not indicative of a functional concern with the axle assembly. However, some customers may find that this "inherent" axle noise is unacceptable. Correction Replace the rear propeller shaft with an aluminum service shaft (utilities) or with a tuned torsional damper shaft (pickups) ONLY after a road test and diagnosis concludes that it is an "inherent" rear axle noise and no physical damage or incorrect adjustment exists. If the noise is not correctly diagnosed as "inherent" and having a peak in the narrow speed range of 72-96 km/h (45-60 mph), the addition of a tuned torsional damper propeller shaft can aggravate the perceptible noise level. It is extremely important to first diagnose the rear axle noise as "inherent" before installing a new tuned torsional damper propeller shaft. Diagnostic Information and Procedures Available in SI for Rear Axle Noise Diagnostic Starting Point - Rear Drive Axle Symptoms - Rear Drive Axle Rear Drive Axle Noises Noisy in Drive Noisy When Coasting The Cadillac Escalade already has a released propeller shaft damper for production. It has a different u-joint size than the 2WD Chevrolet Tahoe and GMC Yukon, so the service propeller shaft in this bulletin would not work on these vehicles. The Escalade has a swaged steel tube shaft with a damper on the end. Page 22983 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 17296 X126 Inline Harness Connector End Views X126 Instrument Panel Harness to Chassis Harness (-JL4) Page 7122 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 12898 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 12190 Vehicle Zoning Strategy Truck Zoning Page 12559 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 8108 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 8977 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 15349 Rear Brake Caliper Bracket Replacement (JH6, JH7) Rear Brake Caliper Bracket Replacement (JH6, JH7) Page 1980 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 4474 Important: When installing a NEW housing the seal will come with the housing. If reusing the housing and then installing a NEW seal follow the instructions for installing the housing and than refer to Crankshaft Rear Oil Seal Replacement to install the seal. 1. Install a NEW housing gasket. 2. Install the NEW housing with the seal using the following procedure. Important: Do not oil or grease the seal lip or the crankshaft seal area. 1. Leave the sleeve in the seal and use the sleeve as a guide to ease installing the seal lip over the end of the crankshaft. 2. Push the housing fully onto the crankshaft until the housing is against the seal gasket and the engine. 3. Remove the sleeve. Notice: Refer to Fastener Notice. 3. Install the crankshaft rear oil seal housing bolts and nut. Tighten the bolts and nut to 12 N.m (106 lb in). 4. Install the engine flywheel. 5. Install the oil pan. Page 24674 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 17346 X123 X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Page 4906 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 12887 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 16493 Inline Harness Connector End Views X501 Left Front Door Harness to Body Harness (YE9 -AN3/DL3) X502 Inline Harness Connector End Views Page 20462 Disclaimer Page 11692 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Diagrams Keyless Entry Receiver: Diagrams Remote Function Connector End Views Remote Control Door Lock Receiver (RCDLR) Page 8159 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 8331 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 945 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 14457 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 2945 Page 18028 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. 3. Dismount the tire from the rim. Important: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 6771 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Service and Repair Fuel Meter Body: Service and Repair Fuel Meter Body Assembly Replacement Removal Procedure Important: An 8-digit part identification number is on a mylar label affixed to the fuel meter body. Refer to this number if servicing or part replacement is required. 1. Remove the upper intake manifold. 2. Reposition both sides of the fuel meter body bracket (1) until the tabs disengage from the fuel meter body, and lift the fuel meter body up. 3. Remove and discard the fuel meter body seal. Notice: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. Page 558 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 5796 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 16220 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 1378 Page 1025 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 18066 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 7285 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 7641 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 23473 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 9868 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 16924 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 23236 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 24018 Ambient Light Sensor: Diagrams HVAC - Automatic HVAC Connector End Views Ambient Light/Sunload Sensor Assembly Page 13975 Disclaimer Page 9165 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 128 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 24539 Note Remove the two relays (1) next to the fuse to gain access to the fuse. 4. Remove the 60 amp heated windshield washer fuse (2) using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Install the two relays (1) removed in Step 4. 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to Step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure that the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 10. Secure the UBEC cover on the UBEC. 11. Close the hood. 12. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 13. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this buleltin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Buick Lucerne, Cadillac DTS and CTS 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS The underhood bussed electrical center is located in the vehicle's front left-hand side of the engine compartment between the engine coolant recovery bottle and rearward of the radiator support housing. The "Heated Windshield Washer" fuse is in location "JC1", which is positioned in the rear center quadrant of the UBEC. 2008-2009 Buick Lucerne and Cadillac DTS The underhood bussed electrical center is located in the vehicle's front left-hand side of engine compartment between the engine coolant recovery bottle and rearward of the radiator support housing. The "Heated Windshield Washer" fuse is in location "F28", which is positioned in the rear inside quadrant of the UBEC. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Page 10599 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 16714 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 12580 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 14348 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 8568 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 10872 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 6214 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 14854 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 8570 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 12483 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. * Tighten the control valve body bolts to 11 N.m (97 lb in). * Tighten the TCC solenoid bolts to 11 N.m (97 lb in). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. Page 8215 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 5914 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 12369 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 20880 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 13116 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 326 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Audio System - Poor AM and FM Band Reception Antenna Cable: All Technical Service Bulletins Audio System - Poor AM and FM Band Reception TECHNICAL Bulletin No.: 06-08-44-033B Date: August 25, 2008 Subject: Radio - Poor AM and FM Reception (Inspect and Fully Seat Connector) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to clarify the location of connector C213 for the Yukon Denali. Please discard Corporate Bulletin Number 06-08-44-033A (Section 08 - Body & Accessories). Condition Some customers may comment that the radio has poor AM and FM reception. Cause The radio antenna coax cable may not be fully seated at connector C213. Correction 1. Remove the driver and passenger windshield pillar garnish molding (A-pillar trim) and disconnect the wiring harness. 2. Remove the instrument panel upper trim panel and disconnect the electrical connections. 3. Remove the foam tape surrounding the radio coax cable electrical connector C213. Connector C213 is located under the top left side of the instrument panel upper trim panel on all vehicles except the Cadillac Escalade EXT and the Chevrolet Avalanche. Connector C213 is located under the top right side of the instrument panel upper trim panel on the Cadillac Escalade EXT, Chevrolet Avalanche and GMC Yukon Denali. 4. Inspect connector C213 and manipulate coax as needed to ensure that the connector is fully seated (The above graphic shows the connector properly seated). 5. Install foam tape around connector C213. 6. If re-securing the connector does not correct the condition, refer to SI for further diagnosis and repair. 7. Install the instrument panel upper trim panel and electrical connections. 8. Install the driver's and passenger's windshield pillar garnish moldings (A pillar trim) and electrical connectors. Warranty Information Page 8498 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (3) up and over the knock sensor. 4. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 5. Lower the vehicle. Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 8107 View of the connector when released from the component. View of another type of Micro 64 connector. Page 16216 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Page 15949 Page 835 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 4752 Timing Cover: Service and Repair Engine Front Cover Replacement Removal Procedure 1. Remove the water pump. 2. Remove the crankshaft balancer. 3. Remove the oil pan. 4. Remove the engine shield bolts and shield. Page 7548 Air Flow Meter/Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Antilock Brake System Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure (W/JL4) Antilock Brake System Automated Bleed Procedure (With JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Using the scan tool, begin the automated bleed procedure. 4. Follow the instructions on the scan tool to complete the automated bleed procedure. Apply the brake pedal when instructed by the scan tool. 5. Turn the ignition OFF. 6. Remove the scan tool from the vehicle. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). 9. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 10. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 11. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 12. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 13. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes 14. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 15. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. (W/O JL4) Antilock Brake System Automated Bleed Procedure (Without JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or Page 16969 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7513 5. Install the appropriate spark plug wire boot(s) (1, 2) to the ignition coil. 6. Inspect the spark plug wires for proper routing (1, 2, 3, 4, 5, 6) and installation. 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 3. Any time the spark plug wire or boot are installed on the spark plug, new dielectric grease needs to be applied inside the boot. Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 6456 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 10690 13. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 N.m (18 lb ft). 14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. 15. Lower the vehicle. 16. Remove the caps from the fuel rail and EVAP line. 17. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. 18. Connect the fuel feed line (1) quick connect fitting to the fuel rail. 19. Install the fuel fill cap. 20. Connect the negative battery cable. 21. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Page 4158 Fuse Block - Underhood X5 (Pin K4 To K8) Fuse Block - Underhood X6 Page 3478 Alignment: Description and Operation Toe Description Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Page 21809 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 12881 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8597 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 6151 Vehicle Zoning Strategy Truck Zoning Page 3999 1 - Fuse Block - Mobile Radio 2 - I/P Structure - Right Side 3 - J224 4 - J219 5 - J209 6 - X219 7 X214 8 - J210 9 - J211 10 - Mobile Radio Blunt Cuts 11 - X226 12 - Instrument Panel G108, G110, G111, and G104 Page 11698 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6922 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 1017 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6090 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 2403 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 15782 1 - Throttle Body 2 - Manifold Absolute Pressure (MAP) Sensor 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Knock Sensor (KS) - 1 5 - Engine Block Heater 6 - Engine Coolant Temperature (ECT) Sensor 7 - Camshaft Position (CMP) Sensor 8 - Generator Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Diagrams Valve Deactivation Solenoid: Diagrams Engine Controls Connector End Views Valve Lifter Oil Manifold (VLOM) Assembly (-4.8L) Page 21134 Page 4972 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 16404 Page 21198 Page 4072 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13869 Transmission Cooler: Service and Repair Allison - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the radiator grille. 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Notice: Refer to Fastener Notice. 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 N.m (106 lb in). 3. Connect the transmission oil cooler lines to the auxiliary cooler. 4. Install the radiator grille. 5. Check and add transmission fluid as necessary. Page 9223 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 16095 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 361 Page 7407 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 1118 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 357 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (JH6/JH7) Electronic Brake Control Module (JH6/JH7) Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheels: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 9049 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 24510 16. Return to the appropriate the Fuse Removal service procedure in this bulletin to continue this repair. Question and Answer Section Question and Answer Section Q1. Why are we compensating customers for a recall? A1. This is a special case where we are not confident a repair would work. This is why we are removing this feature from the vehicle. Compensating the current customer of record for this loss is an appropriate gesture. Q2. What is the original cost of the Heated Washer Fluid System? A2. The system was priced in several ways; as standard equipment, as a stand-alone option and as part of an option package. We analyzed these scenarios and determined that $100 is an appropriate estimate of the value of the feature. Q3. How much will each customer receive? A3. Customers will receive a $100 check from their servicing dealer within 30 days of recall completion. Q4. Why can't GM issue the checks? A4. Due to their age, our original sales records will not reflect any subsequent vehicle transactions or owner changes. Additionally, we don't have an in-house system that can handle this number of checks. So we are depending on our dealers to help execute this safety recall. Q5: When will customers be notified about having this feature disabled? A5: Customers should begin receiving letters in the mail in mid-June. However, they can go to their local dealer any time (even in advance of receiving a letter) to have the system disabled. Q6. Are all of the VINs involved in this recall identified in the GWM-IVH (GMVIS2) application? A6. Yes, all involved VINs have been updated for this recall. Q7. How do I identify the current customer of record? A7. For the purposes of this recall, the current customer of record is to be identified as the person or company whose name appears on the vehicle's state registration document or other legally recognized proof of vehicle ownership (unless specifically excluded). Prior to issuing the $100.00 check, please ensure the proof of ownership documentation has not expired and is otherwise valid. Q8. What should I do if proof of vehicle ownership is not available? A8. If proof of vehicle ownership documentation is not currently available or is otherwise invalid, the $100 check should not be issued. Q9. What if the customer objects to this policy? A9. If valid proof of ownership documentation is not available, the decision not to issue the $100 check is correct. If the customer still disagrees, please refer him/her to the GM Customer Assistance Center. Q10. If a check is not issued, how should the recall claim be submitted? A10. If a final determination is made not to issue a check, the $100 net item amount should not be claimed. Only the labor cost for the repair should be submitted. Q11. Can you provide examples of the various customer scenarios I can expect? A11. Certainly, listed below are examples with the preferred resolution. ^ Retail Customer - Vehicle Purchased Issue check to the customer at vehicle pickup if valid proof of vehicle ownership documentation is available. All checks must include the complete 17 character Vehicle Identification Number. ^ Retail Customer - Vehicle Leased Issue check to the customer at vehicle pickup (not GMAC or other financial institution) if valid proof of vehicle ownership documentation is available. Page 6148 Page 10672 Notice: Refer to Fastener Notice. 5. Install the fuel pipe bracket bolt (2). Tighten the bolt to 6 N.m (53 lb in). 6. Install the fuel pipe retainer nuts (1). Tighten the nuts to 3 N.m (27 lb in). 7. Remove the caps from the fuel pipes. 8. Connect the chassis fuel feed pipe (1) to the engine compartment feed pipe. 9. Test the system for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Page 4116 Fuse Block - I/P X2 Page 22950 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 3053 Notice: Failure to properly align the crankshaft position sensor reluctor ring may result in component damage and effect OBD II system performance. Important: The reluctor ring is shaped like a dish. The dish must face the engine front cover. Failure to do so will damage the front cover and the reluctor ring. 1. Install the CKP sensor reluctor ring. 1. Align the keyway on the CKP sensor reluctor ring with the key in the crankshaft. 2. Using J 5590, push the CKP sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. 2. Install the engine front cover. Page 2540 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 10781 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 3185 Air Bag Deactivation Switch: Diagrams Inflatable Restraint I/P Module Disable Switch (C99) Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 24742 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 20204 Entertainment System Control Module: Service and Repair Audio System Transceiver Module Replacement Page 2750 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 5083 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 15384 Page 7234 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 5831 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 16895 Page 19450 For vehicles repaired under warranty use, the table. Disclaimer Page 1072 Fuel Pump Relay: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 2717 Page 14750 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 16203 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 21511 Page 5966 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Locations Knock Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 14464 11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm blow from a dead blow hammer. 12. It may be necessary to lubricate the snap ring with a slight amount of chassis grease so that the snap ring seats in the bearing cup groove. Page 2273 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 7127 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 8312 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 24680 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 17078 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 13211 Page 760 Hazard Flasher Relay: Diagrams Wrecker Relay X1 (5X7) Power and Grounding Connector End Views Wrecker Relay X1 (5X7) Page 6674 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 4368 Wheel Bearing: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 15790 4. Install the engine wiring harness lead (4) to the generator stud. 5. Install the engine wiring harness nut (3) to the generator. Tighten the nut to 9 N.m (80 lb in). 6. Position the engine wiring harness boot (6) over the generator stud. 7. Connect the engine wiring harness electrical connector (5) to the generator. 8. Install the heater outlet hose clamp bolt (1) at the generator bracket. Tighten the bolt to 25 N.m (18 lb ft). Page 20623 Subject: Squeaky Outside Door Handle (Grease U-Channel of Handle) Models: 2007-2008 Cadillac Escalade, Escalade EXT, Escalade ESV 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Condition Some customers may comment on a squeak noise coming from the door handle as the handle is actuated. Cause This condition may be caused by the pin and the inside of pawl surface making contact with each other, resulting in a squeak noise. Correction DO NOT REPLACE THE DOOR HANDLE. 1. Remove the fasteners to the door handle, leaving the rod to the latch attached. 2. Apply a generous amount of dielectric silicone grease, P/N 12345579 (in Canada, 10953481), as shown in the graphics, into the U-channel of the handle between the pawl and the tower where the gray pin enters through the spring and the pawl. 3. Cycle the handle at least 20 times to work the grease around the pin and to make sure that the squeak has been eliminated. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 09-08-64-032A Date: 110418 Body - Chrome Outside Door Handle Loose/Cracked TECHNICAL Bulletin No.: 09-08-64-032A Date: April 18, 2011 Page 4912 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 12485 powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 12. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 16596 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 13527 Page 1049 Engine Control Module: Description and Operation Engine Control Module Description The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The engine control module (ECM) is the control center of this system. The ECM monitors numerous engine and vehicle functions. The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The ECM also performs the diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the ECM detects a malfunction, the ECM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the ECM. Malfunction Indicator Lamp (MIL) Operation The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: * The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. * The MIL turns OFF after the engine is started if a diagnostic fault is not present. * The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. * The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. * When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. * When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Page 18122 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 14225 6. Install the J 8614-01 as shown. 7. While holding the J 8614-01, loosen the pinion nut. 8. Remove the washer. 9. Remove the pinion nut and washer. 10. Install the J 8614-2 (2) and the J 8614-3 (3) into the J 8614-01 (1) as shown. 11. Remove the pinion yoke by turning the J 8614-3 (3) clockwise while holding the J 8614-01 (1). Use a container in order to retrieve the lubricant. Page 9089 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 834 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 5463 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 9033 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 8961 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 10048 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 16991 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 4142 Junction Block - Right I/P X6 Page 6331 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 23613 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 8427 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 15085 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Page 9445 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 22137 11 - Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) 12 - Seat Adjuster Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor Passenger (AN3) Page 9119 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Service and Repair Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Page 6078 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 19015 Seat Belt Buckle: Service and Repair Rear Seat Center Belt Buckle Replacement (Ext Cab w/A68) Rear Seat Center Belt Buckle Replacement (Ext Cab w/A68) Page 21637 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 13635 from the bores. Be sure to catch the accumulators and springs so as to prevent damage to these parts. * The pressure control valve retaining bracket (5) must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or more. To remove the pressure control solenoid 1 (PCS1) or PCS2, remove three bolts (4) and the pressure control valve retaining bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when the bracket (5) is removed. 4. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal. Installation Procedure 1. Obtain the new solenoid (1) or (8). Lubricate new O-ring (2) or (7) with clean transmission fluid. Install the O-ring and push the new solenoid into the control valve body bore with the wiring harness connector in the correct position. 2. Install the 2 accumulators (3) and springs (6) before installing the pressure control valve retaining bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. Notice: Refer to Fastener Notice. 3. Install the pressure control valve retaining bracket (5), and install the 3 bolts (4). Tighten the bolts to 12 N.m (108 lb in). Page 7427 4. Reposition the knock sensor sleeve (2) down, away from the knock sensor. 5. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. 6. Remove the knock sensor bolt and sensor. Installation Procedure Page 16903 Page 11002 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 17467 Not all of the effects or driver notifications listed above have been experienced. However, the different effects and driver notifications may be caused by one of the wires in the IP harness being chafed or cut. Components on different lines in the list above are in different circuits. Due to the cause of the condition, and the positions of the wires in the IP harness, it is unlikely that more than one circuit will be affected by the condition. Upon investigation, the technician may find several DTCs set as current or in history. The technician may also find one or more blown fuses in the IP and underhood fuse blocks. The potential fuses are listed below: 60 amp MBEC1 (# 72) (Underhood) 30 amp AMP (# 40) (Underhood) 15 amp RDO (# 41) (Underhood) 10 amp IPC (# 46) (Underhood) 15 amp AIRBAG BATT (# 51) (Underhood) 10 amp DSM (Left side of IP) Cause The condition may be caused by one of the wires in the IP harness being chafed or cut on the parking brake pedal assembly. Five areas of potential contact have been identified and are shown. Page 15277 Caution: Refer to Brake Dust Caution. Important: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. See: Brake Rotor Thickness Measurement * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Brake Rotor Assembled Lateral Runout Measurement 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement. See: Brake Rotor Thickness Measurement 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Brake Rotor Assembled Lateral Runout Measurement 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction. See: Brake Rotor Assembled Lateral Runout Correction 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. Brake Rotor Assembled Lateral Runout Measurement Brake Rotor Assembled Lateral Runout Measurement Tools Required * J 39544-KIT Torque-Limiting Socket Set, or equivalent * J 41013 Rotor Resurfacing Kit * J 42450-A Wheel Hub Resurfacing Kit * J 45101 Hub and Wheel Runout Gage * J 45101-100 Conical Brake Rotor Washers Caution: Refer to Brake Dust Caution. Important: * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. See: Brake Rotor Thickness Measurement 1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already. Page 13647 Shifter A/T: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Range Selector Lever Replacement Page 21762 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 11572 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 1089 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6590 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 5176 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 13297 Visually inspect and pull on the C2 Audio Amplifier Connector (1). If the connector is properly seated, then refer to SI for further diagnosis based on the customers condition. If the connector is loose, then reinstall the C2 Audio Amplifier Connector. Verify the connector is seated and locked into place. Install the fuses. Verify the condition has been fixed and clear any DTCs. If securing the connector does not correct the condition, refer to SI for further diagnosis and repair. Install the radio speaker amplifier assembly and any other components removed to gain access to the amplifier. Refer to Radio Speaker Amplifier Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2077 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 6748 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 5252 Radiator: Service and Repair Radiator Vent Inlet Hose Replacement Radiator Vent Inlet Hose Replacement (Non-HP2) Page 10978 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 14878 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 6426 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Tank Pressure Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 24657 Page 22435 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Body - Water Leaks Into Rear Footwell Area Rear Door Panel: Customer Interest Body - Water Leaks Into Rear Footwell Area Bulletin No.: 07-08-64-004 Date: February 28, 2007 TECHNICAL Subject: Wet or Stained Carpeting in Rear Footwell After Heavy Rainfall or Car Wash (Replace Water Deflector) Models: 2007 Chevrolet Silverado Extended Cab (New Body Style) 2007 GMC Sierra Extended Cab (New Body Style) Condition Some customers may comment on wet or stained carpeting in the rear footwell after a very heavy rainfall or high pressure car wash. Cause This condition may be caused by a void in the loft area around the map pocket on the TIAS water protector (water deflector) inside the door trim. This loft area normally creates an interference condition, causing the adhesive bead to wet out and seal off the water. When a void is present, water intrusion may occur. Correction Carefully remove the interior rear side door trim panel. Refer to Rear Side Door Trim Panel Replacement (YE9 or SLT) in SI. Inspect the water deflector for a missing loft. Refer to the illustration above for an example of a correct loft (1) and a missing loft (2). If the loft is missing, replace the water deflector with a new service part. Inspect the opposite side door and replace the opposite side water deflector if necessary. Refer to Rear Side Door Water Deflector Replacement in SI. Parts Information Warranty Information Page 395 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 7139 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 11188 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 9209 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 3654 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 12659 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 538 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 3119 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 10548 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 16905 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 7170 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 14495 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 9464 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 18748 Inflatable Restraint Sensing and Diagnostic Module (SDM) (10 Series -ASF) Page 11749 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (7) from the camshaft position (CMP) sensor wiring harness jumper. 2. Remove the water pump. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor and wiring harness jumper from the engine front cover. 5. Disconnect the CMP sensor wiring harness jumper from the CMP sensor. 6. Remove the CMP sensor from the wiring harness jumper. Installation Procedure Page 24301 Page 8324 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 16786 Page 17586 Alignment: Description and Operation Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Page 12738 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 1376 Passenger Door Switch (PDS) X4 (AN3) Page 12918 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. Tighten the bolt to 12 N.m (108 lb in). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Page 10697 16. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 N.m (18 lb ft). 17. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP line. 20. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. 21. Connect the fuel feed line (1) quick connect fitting to the fuel rail. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Page 11544 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 9114 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 16773 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 15853 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 13543 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3146 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 15657 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement (With RPO JL1 and Without JL4) Page 4836 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8-11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8-11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kpa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. * Normal The compression builds up quickly and evenly to the specified compression. * Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. * Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Page 7201 Page 9367 4. Remove the CKP sensor bolt and sensor. Installation Procedure Important: When installing the CKP sensor, make sure the sensor is fully seated before tightening the bolt. A poorly seated CKP sensor may perform erratically and may set false diagnostic trouble codes (DTCs). Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CKP sensor, install a NEW O-ring seal onto the sensor. 2. Lubricate the O-ring seal with clean engine oil. Notice: Refer to Fastener Notice. 3. Install the CKP sensor and bolt. Tighten the bolt to 10 N.m (89 lb in). Page 12578 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 1815 View of the connector when released from the component. View of another type of Micro 64 connector. Page 21900 Locations: The locations for the Connectors, Grounds, Splices, and Grommets shown within these diagrams can be found via their numbers at Vehicle Locations. See: Locations Page 2406 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. Remove the tire from the wheel. Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 3. Remove the tire pressure sensor nut. 4. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Electronic Brake Control Module (JL4) Electronic Brake Control Module: Diagrams Electronic Brake Control Module (JL4) Electronic Brake Control Module (JL4) Page 14831 Page 19711 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Page 12690 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 17713 Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Place drain pans under the vehicle as needed. Page 7391 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 7902 Page 1667 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 5512 Catalytic Converter: Service Precautions Three-Way Catalytic Converter Damage Notice Notice: In order to avoid damaging the replacement three-way catalytic converter, correct the engine misfire or mechanical fault before replacing the three-way catalytic converter. Page 20692 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 514 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 21882 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Heater Inlet Hose Replacement (Non-HP2) Heater Hose: Service and Repair Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. Page 7148 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 8559 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 9351 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 2458 Page 7990 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 11934 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 1130 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 17539 The IP wiring branch to C202 (IP to body cam lock connection) may have been routed outboard of the junction block (left IP) and the retaining clip (1) off the branch may not have been seated. Possible point of contact (2). The IP wiring branch to C202 may have been pushed up and forward into the park brake assembly and the retaining clip off the branch may not have been seated. Possible points of contact (1, 2). The IP wiring branch to C202 may have never been secured into place (gray retaining clip (1) off the branch was never seated). Page 23945 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 5162 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 5163 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 1771 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 14058 Control (with Body and Valve) Valve Assembly 301 - Bolt, M5 x 36 mm 302 - Bolt, M6 x 20 mm 303 - A/Trans Input and Output Speed Sensor Assembly 304 - Control Valve Upper Body Assembly 305 - Control Valve Body Spacer (w/ Gasket) Plate Assembly Page 1033 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 10454 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 11756 Page 24221 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 10170 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 7671 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 11563 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Locations Auxiliary Battery Relay: Locations Auxiliary Battery Harness (TP2) 1 - Fuse Holder - Underhood 2 - Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 23664 Dimmer Switch: Diagrams Lighting Systems Connector End Views Headlamp and Panel Dimmer Switch Page 21218 5. Install the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 6. Connect the trailer wiring harness connector (3) to the trailer wiring recepticle (4). Page 12838 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 16257 Page 16474 X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Page 15592 Page 24549 All checks must include the complete 17 character Vehicle Identification Number. ^ Fleet Customer - Daily Rental (Avis, Budget, Enterprise, etc.) Issue check to the daily rental company if valid proof of vehicle ownership documentation is available. Confirm local address and mail or provide check to their representative at vehicle pickup. All checks must include the complete 17 character Vehicle Identification Number. ^ Fleet Customer - Lease Management Company (PH&H;, GE Capital, ARI, etc.) Issue check to the lease management company if valid proof of ownership documentation is available. Ask the customer where the check should be mailed. Approximately 7,500 vehicles are involved and these customers will be receiving a letter from their lease management company explaining this situation. All checks must include the complete 17 character Vehicle Identification Number. Q12. What should I do if a customer refuses to have the recall service procedure performed on his/her vehicle? A12. If a customer initially declines the recall repair, please make sure that he/she fully understands the possible consequences. Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (HWFS). As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 10153. - Schedule an appointment with your GM dealer/retailer. - This service will be performed for you at no charge. Why is your vehicle being recalled? A recall was implemented on some vehicles in 2008 to add a fuse to the HWFS control circuit harness to address the potential consequences of a printed circuit board electrical short. However, there have been new reports of thermal incidents on HWFS modules after this improvement was installed. These incidents resulted from a new failure mode attributed to the device's thermal protection feature. Their significance varies from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. What will we do? Your GM dealer/retailer will permanently disable and remove the heated washer fluid system. In addition, because the heated washer feature will be disabled, the dealer will provide a customer satisfaction payment of $100 to the customer. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer/retailer will need your vehicle longer than the actual service correction time of approximately 20 minutes. An updated page for your Owner Manual will be provided and inserted at the time of service to document that the feature has been permanently disabled and removed from your vehicle. If your vehicle is within the New Vehicle Limited Warranty, your dealer/retailer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership/facility for this repair. Please refer to your Owner Manual and your dealer/retailer for details on courtesy transportation. What should you do? You should contact your GM dealer/retailer to arrange a service appointment as soon as possible. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition repaired in the past, you will still need to take your vehicle to your dealer/retailer for this recall. Page 21842 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 11657 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Remove the knock sensor heat shield bolt and shield. Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 7128 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 6288 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 7326 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 2855 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 9197 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 9181 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 6157 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 2516 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 12220 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Restraints - Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 7894 lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If re-installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. Notice: Refer to Fastener Notice. 2. Install the ECT sensor to the cylinder head. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 15888 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 22937 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 16437 Page 9308 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 1073 Page 10405 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11665 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 1151 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 21615 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 1955 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 7093 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 9310 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 14068 12. Inspect the transmission fluid pressure manual valve position switch assembly for the following conditions: * Damage * Debris * Damaged or missing O-rings * Cracked connector * Loose electrical terminals * Poor terminal retention 13. Remove the manual detent spring bolt. 14. Remove the manual detent spring. 15. Inspect the manual detent spring for cracks or damage. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 16. Remove the remaining valve body bolts. Page 5900 Fuel Pump Relay: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 14889 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 9189 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 1064 Upper Control Arm Replacement Control Arm: Service and Repair Upper Control Arm Replacement Upper Control Arm Replacement (1500) Page 19117 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended Cab +ASF) Page 7396 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 9406 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 4118 Fuse Block - I/P X4 Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: All Technical Service Bulletins Park Assist System Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Page 22923 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 600 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 6314 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 9206 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 5529 7. Remove the exhaust manifold bolts. 8. Remove the exhaust manifold and gaskets (1). Discard the gaskets. 9. Remove the exhaust manifold to catalytic converter seal (2). Discard the seal. Installation Procedure 1. Install a NEW exhaust manifold to catalytic converter seal (2) into the exhaust manifold. 2. Place the exhaust manifold into position and install the manifold studs to the catalytic converter. 3. Place the NEW exhaust manifold gaskets (1) between the manifold and the cylinder head. Notice: Refer to Fastener Notice. 4. Install the exhaust manifold bolts and stud. Tighten the bolts/stud to 30 N.m (22 lb ft). Page 5068 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15608 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 14083 Page 24561 to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Owner Letter Owner Letter September 2008 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2006-2008 model year Buick Lucerne; Cadillac DTS; HUMMER H2 vehicles; 2007-2008 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK vehicles; and 2008 model year Buick Enclave vehicles equipped with a heated washer fluid system. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 08048. - Schedule an appointment with your GM dealer/retailer on or after November 1, 2008. Why is your vehicle being recalled? A short circuit on the printed circuit board for the washer fluid heater may overheat the control-circuit ground wire. This may cause other electrical features to malfunction, create an odor, or cause smoke. In rare cases, it may cause a fire. What will we do? When parts are available, your dealer/retailer will install a wire harness with an in-line fuse. This service will be performed for you at no charge. We are currently working with our suppliers, and parts should be available on or after November 1, 2008. If your vehicle is within the New Vehicle Limited Warranty your dealer/retailer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership/facility for this repair. Please refer to your Owner Manual and your dealer/retailer for details on courtesy transportation. What should you do? On or after November 1, 2008, you should contact your GM dealer/retailer to arrange a service appointment. Bring the customer reply form with you when you visit your dealer/retailer. The form identifies the repairs required. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us. If your vehicle experiences any of the symptoms described earlier in this letter, please bring your vehicle to the dealer. Do you have questions? If you have questions or concerns that your dealer/retailer is unable to resolve, please contact the appropriate GM Customer Assistance Center. More information about this recall can be found at the Owner Center at MyGMLink, http://www.gm.com/recall. If after contacting your dealer/retailer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Page 6448 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 21100 Hood Sensor/Switch (For Alarm): Diagrams Immobilizer Connector End Views Hood Ajar Switch (AP3/AP8) Page 16082 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4101 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 1860 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 19681 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 4946 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 22982 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 5090 Page 19256 Antenna Cable: Service and Repair Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Page 4960 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 241 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 5786 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 15166 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Page 13557 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 9109 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 11435 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 18021 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 10814 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 19696 - 15882767 - 15940102 - 15940103 - 25797978 - 25834072 Update the Navigation Radio's software to correct this condition. This software upgrade will also update some operating characteristics on the Navigation Radio. The following functions or displays may be affected: Important Inform the customer that stored destinations and radio presets may not be retained during programming. - Clock font size - Text color on light colored screens - Split screen icon to minimize the "Points of Interest" popup and "Exit" popup - Destination keyboard characters moved from page 2 to page 1. - "Back" button on street address entry screen for entering street number - User selectable lock-outs for XM Categories, music Navigator, MP3 folders, address book, POI's and Turn list. - "I Agree" screen changed from every ignition cycle to once in every 50 ignition cycles. - Screen Brightness adjustment not disabled while vehicle is in motion. How to Obtain Nav Software Update Disc (P/N 25956121 - software version 0B92): Software discs are available through the GM Nav Disc Center. Dealers should treat the disc like a special tool and retain the disc for use in repairing future vehicles. DO NOT give the software disc to the customer. Navigation Software Update Procedure: Use the following procedure to update the Navigation Radio software using the Nav Software Update Disc P/N 25956121 (software version 0B92): Important - This software update can only be used to update the navigation radios specified in this bulletin. DO NOT use this software to update any other vehicle's navigation radio. - The Map DVD will be needed to verify the system operation after the software update has been performed. Use the vehicle's existing map DVD. - It is recommended to wear latex gloves while performing the software update, to avoid fingerprints on the product and discs. The software update requires using the map DVD slot. The update will not work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Notice DO NOT stop the engine until all tasks are completed. The software update MUST be performed with the engine RUNNING and the gear position in PARK. If the vehicle is turned off prior to the software update being completed, the process may not work again and a new Navigation Radio may be required. 1. Start the engine with the gear selector in PARK. Wait until the audio or caution screen is displayed after the opening screen. 2. Press the "NAV" hard key. 3. Press "OK" soft key. 4. Press the "MENU" hard key. 5. Press the "NAV" soft key. 6. Press the "MAP DATABASE INFORMATION" soft key. 7. Press the "CHANGE" soft key. Lower Intake Manifold Replacement Intake Manifold: Service and Repair Lower Intake Manifold Replacement Lower Intake Manifold Replacement Removal Procedure Important: * The intake manifold may be removed as an assembly. Do not remove the specific intake manifold components unless component service is required. * It is not necessary to remove the upper intake manifold in order to remove the lower intake manifold. * Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the fuel system are properly sealed. * Do not disassemble the central sequential fuel injection (SFI) unit, unless service is required. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Remove the fuel pipes/hoses. 3. Remove the ignition coil assembly. 4. Remove the evaporative emission (EVAP) canister tube. 5. Remove the heater hose clamp (1). 6. Open the heater outlet hose clamp and remove the hose from the intake manifold. 7. Open the heater inlet hose clamp and remove the hose from the water pump. Page 1046 Engine Control Module X1 (Pin 25 To 73) Engine Control Module X2 Page 11730 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 2423 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 9546 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Reposition the knock sensor sleeve (3) down, away from the knock sensor. 4. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. Page 13711 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 11745 Page 21907 Memory Seat Module X6 (AN3) Page 13895 Transmission Mode Switch: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Internal Mode Switch (IMS) Internal Mode Switch (IMS) Page 20167 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Page 5850 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 8932 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 7184 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Caution Caution: Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 23150 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 9122 Page 16214 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 577 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 2866 View of the connector when released from the component. View of another type of Micro 64 connector. Page 15017 Fluid Pressure Sensor/Switch: Specifications Allison - Automatic Transmission Pressure Switch Manifold (PSM) Logic Pressure Switch Manifold (PSM) Logic Page 13787 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 11388 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 2641 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 1923 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 9211 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 7913 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 2615 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 14902 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 20805 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Locations Intake Air Temperature Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Allison - Automatic Transmission Transmission Speed Sensor: Service and Repair Allison - Automatic Transmission Speed Sensor Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Page 15185 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Page 2480 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 14192 Pinion Gear: Service and Repair Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion gear bearing retainer. 4. Remove the pinion and the pinion bearings. 5. Remove the ring gear bolts. Discard the bolts. Notice: Refer to Ring Gear Removal Notice. 6. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case as shown. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 2. Install the ring gear to the differential case. 3. Install the new ring gear bolts. Page 13123 powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 12. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 4444 1. Install the pushrods. Important: Be sure that the arrow on the rocker arm support is in the up position. 2. Install the rocker arm supports. 3. Apply lubricant to the following rocker arm contact surfaces: * Pushrod socket (1) * Roller pivot (2) * Valve stem tip (3) Refer to Sealers, Adhesives, and Lubricants for the correct part number. Page 12316 Control Module: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (MW7) 1 - Transmission Control Module 2 - Transmission Control Module Connector 3 - Radiator Fan Shroud Page 13561 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 184 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 13291 Visually inspect and pull on the C2 Audio Amplifier Connector (1). If the connector is properly seated, then refer to SI for further diagnosis based on the customers condition. If the connector is loose, then reinstall the C2 Audio Amplifier Connector. Verify the connector is seated and locked into place. Install the fuses. Verify the condition has been fixed and clear any DTCs. If securing the connector does not correct the condition, refer to SI for further diagnosis and repair. Install the radio speaker amplifier assembly and any other components removed to gain access to the amplifier. Refer to Radio Speaker Amplifier Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 20628 Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Replacement Page 12056 Page 17904 For vehicles equipped with electronic suspension, tighten the nut (3) to 50 N.m (37 lb ft). Tighten For vehicles without electronic suspension, tighten the nut (3) to 60 N.m (44 lb ft). Remove the shock absorber assembly from the spring compressor. Install the strut assembly in the vehicle. Refer to Shock Absorber and Spring Assembly Replacement. Disclaimer Page 18279 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 3683 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027) Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 3. Remove the engine cover, if required. 4. Remove the fuel rail service port cap. 5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 7. Install the fuel rail service port cap. 8. Install the engine cover, if required. 9. Tighten the fuel fill cap. Page 7971 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 2125 4. Connect the engine wiring harness electrical connector (4) to the CKP sensor. 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. 7. Perform the crankshaft position system variation learn procedure. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 22189 Page 8995 Engine Control Module: Service and Repair Engine Control Module Replacement Service of the engine control module (ECM) should consist of either replacement of the ECM or programming of the electrically erasable programmable read only memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used. If the correct part is being used, remove the faulty ECM and install the new service ECM. Notice: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Important: It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last oil change. Removal Procedure 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. 3. Disengage the engine wiring harness upper electrical connector retainer (2) and remove the connector (1) from the ECM. 4. Disengage the engine wiring harness lower electrical connector retainer (3) and remove the connector (4) from the ECM. Page 19456 For vehicles repaired under warranty, use the table. Disclaimer Page 417 Page 24512 Do you have questions? If you have questions or concerns that your dealer/retailer is unable to resolve, please contact the GM Customer Assistance Center. More information about your vehicle can be found at the GM Owner Center at www.gmownercenter.com. If after contacting your dealer/retailer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Scott Lawson Director, Customer and Relationship Services Enclosure 10153 Division Owner Letter Division Owner Letter Page 2715 Service and Repair Hydraulic Fluid Accumulator: Service and Repair Hydraulic Brake Booster Accumulator Replacement Tools Required j 26889 Accumulator Piston Compressor Removal Procedure Caution: The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or personal injury may result. Do not apply heat to accumulator. Do not attempt to repair an inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 in) diameter hole through the end of the accumulator can, opposite the O-ring. Caution: Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. 1. Apply the park brake and block the wheels. 2. Depress brake pedal at least 10 times in order to relieve pressure in the accumulator. 3. Remove the master cylinder from the hydraulic booster. 4. Place the J 26889 over the end of the accumulator. 5. Install the nut on the stud. 6. Depress the accumulator with a C-clamp. If the accumulator does not move with moderate pressure, remove the C-clamp and depress the brake pedal ten times in order to relieve pressure in the accumulator. 7. Rotate the retaining ring (2) until either end of the ring is under the access hole (1). Page 7277 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9502 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 20614 For vehicles repaired under warranty, use the table above. Disclaimer Page 2547 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 1902 Page 22450 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 9558 Important: Note the alignment of the engine oil pressure sensor fitting prior to removal. 3. Remove the fuel pump/oil pressure sensor fitting, if necessary. Installation Procedure 1. If installing the old fitting, apply sealant to the threads of the fitting. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 2. Install the fitting until snug, if necessary. Notice: Refer to Fastener Notice. 3. Tighten the fuel pump/oil pressure sensor fitting. 1. Tighten the fitting to 15 N.m (11 lb ft). 2. Increase torque until the centerline of the fitting (1) is 50 degrees from the centerline of the crankshaft (2). Page 2426 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 9624 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 465 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 3327 Fluid Pressure Sensor/Switch: Diagrams Automatic Transmission Internal Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Page 8227 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Tank Pressure Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 14885 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 2983 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Parking Brake Release Handle Assembly Replacement Parking Brake Lever: Service and Repair Parking Brake Release Handle Assembly Replacement Parking Brake Release Handle Assembly Replacement Page 7851 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 1927 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 15774 1. Install the battery tray to the vehicle. Notice: Refer to Fastener Notice. 2. Install the 3 nuts securing the battery tray to the battery tray bracket. Tighten the nuts to 20 N.m (15 lb ft). 3. Install the nut securing the battery tray to the front fender inner panel. Tighten the nut to 9 N.m (80 lb in). 4. Install the battery tray front support. 5. Install the battery tray front support bolts. Tighten the bolts to 20 N.m (15 lb ft). Page 4626 9. Remove the differential carrier left side bolts. 10. Lower the differential carrier. 11. For 2500 series vehicles, remove the differential carrier right side nuts. 12. Remove the differential carrier upper mounting bolt and nut. 13. Remove the differential carrier lower mounting bolt and nut. Page 6253 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (7) from the camshaft position (CMP) sensor wiring harness jumper. 2. Remove the water pump. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor and wiring harness jumper from the engine front cover. 5. Disconnect the CMP sensor wiring harness jumper from the CMP sensor. 6. Remove the CMP sensor from the wiring harness jumper. Installation Procedure Page 6111 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 2303 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Reposition the knock sensor sleeve (3) down, away from the knock sensor. 4. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. Page 7646 Air Flow Meter/Sensor: Connector Views Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 14991 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 5071 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 7120 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 3087 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 7579 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 21973 Sun Shade: Service and Repair Sunroof Sunshade Stop Replacement Sunroof Sunshade Stop Replacement Page 5470 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 7916 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 17035 Page 3013 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 24146 Page 10952 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Service and Repair Seat Belt Latch: Service and Repair Seat Belt Latch Stop Installation Page 5527 5. Install the spark plugs. 6. Position the exhaust manifold heat shield to the manifold and install the bolts. Tighten the bolts to 9 N.m (80 lb in). 7. Raise and support the vehicle. 8. Install the catalytic converter to exhaust manifold nuts (1). Tighten the nuts to 50 N.m (37 lb ft). 9. Lower the vehicle. Page 20324 2. Place the AT in Park (P) or the MT in the lowest gear (1st). 3. Securely attach the vehicle being towed to the tow vehicle. Caution: Shifting the transfer case to Neutral can cause the vehicle to roll, even if the transmission is in park (automatic) or 1st gear (manual), and may cause personal injury. 4. If equipped, place the transfer case shift lever in Neutral (N). Note: Use extra care whenever towing another vehicle. Do not exceed the towing vehicle's gross combination weight (GCW) by adding the weight of the dinghy towed vehicle or vehicle damage may result. 5. When the vehicle being towed is firmly attached to the tow vehicle, release the parking brake. 6. The Owner's Manual specifies the appropriate ignition key position to ensure that the steering is unlocked to allow the front wheels to follow the tow vehicle. Rear Wheel Drive Light Duty Trucks Important: ^ Dust or dirt can enter the back of the transmission through the opening created by the removal of the slip yoke from the transmission if proper protection is not provided. ^ Verify that the transmission fluid is at the proper level before driving the truck. Rear wheel drive vehicles, equipped with AT or MT, should NOT be dinghy towed. These transmissions have no provisions for internal lubrication while being towed. In order to properly tow these vehicles, place the vehicle on a platform trailer with all four tires off the ground. Avoid towing the vehicle with all four tires on the ground. In rare instances when it is unavoidable that a rear wheel drive vehicle be dinghy towed, the propeller shaft to axle yoke orientation should be marked and the propeller shaft removed. Refer to the applicable Service Manual for procedures on propeller shaft removal/installation. Transfer Case Identification Page 1281 Control Module: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Page 12786 Shift Interlock Solenoid: Diagrams Shift Lock Control Connector End Views A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid Page 5027 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 24651 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 5847 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required j 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the oil pressure sensor. Do not allow debris to enter the engine. 1. Disconnect the fuel pump/oil pressure sensor electrical connector (3). 2. Using J 41712, remove the fuel pump/oil pressure sensor. OnStar(R) - Language Change Information Navigation System: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Page 22446 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 6761 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 22139 Seat Adjuster Assembly - Driver X2 (AN3) Seat Adjuster Assembly - Passenger (AG2) Page 9121 Page 15593 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (JH6, JH7) Electronic Brake Control Module Replacement (JH6, JH7) Page 13824 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 7866 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 12359 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 8373 Information Bus: Testing and Inspection Scan Tool Does Not Communicate with Low Speed GMLAN Device Scan Tool Does Not Communicate with Low Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description Modules connected to the low speed GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules when the ignition switch is in any position other than OFF. The low speed GMLAN serial data circuit must be operational for the vehicle to start so the vehicle theft deterrent (VTD) module and body control module (BCM) can communicate. The low speed GMLAN serial data circuit uses SP203 as the common connection between the modules and the data link connector (DLC). Diagnostic Aids * Use the Data Link References to identify the low speed GMLAN serial data modules. * This test is used for a total low speed GMLAN communication failure. If only 1 module is not communicating and sets no DTC, ensure that the vehicle is equipped with the module, then use DTC U0100-U0299 for diagnostics. * An open in the low speed GMLAN serial data circuit between the splice pack and a module will only effect the specific module. This type of failure will set a loss of communication DTC for each module effected, and the other modules will still communicate. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate to set up the vehicle on the tool and then not communicate with the vehicle. When the scan tool is to the point of communicating with the vehicle, a message on the scan tool will indicate "no CANdi module detected" and will not communicate. * An open between the DLC and C 203 will only effect the communication with the scan tool. The vehicle modules will still communicate, and the vehicle will start. * The engine will not start when there is a total malfunction of the low speed GMLAN serial data circuit. The following conditions may cause a total loss of low speed GMLAN data communication: - The low speed GMLAN serial data circuit shorted to ground or voltage. - A module internal malfunction that causes a short to voltage or ground on the low speed GMLAN circuit. * Use the DMM MIN/MAX function to capture/locate intermittent conditions. Circuit/System Testing 1. Test for less than 1 ohm of resistance between the DLC ground circuit terminal 5 and ground. ‹› If greater than 1 ohm, test the ground circuit for open/high resistance. 2. Ignition OFF, disconnect the harness connector at splice pack SP 300. 3. Ignition ON, with a scan tool, attempt to communicate with the instrument panel cluster (IPC). Communication should be available. ‹› If no communication, disconnect the modules still connected to the DLC one at a time, starting with the furthest from the DLC and attempt to communicate after each disconnect. When communication occurs, test the serial data circuit for a short to ground and a short to voltage between the last module disconnected and the previous module disconnected. If the circuit tests normal, replace the last module disconnected. If no communication is possible, test the serial data circuit for a short to ground, a short to voltage or an open/high resistance between the last Page 9120 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 14553 Control Module: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Control Module Replacement Page 19074 Disclaimer Page 10455 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 1871 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 15686 Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JH6/JH7) Wheel Speed Sensor (WSS) - Right Front (JH6/JH7) Page 12988 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 9008 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Page 14726 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 4587 2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. 3. Apply threadlocker GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the bolts. Notice: Refer to Fastener Notice. 3. Install the engine mount bracket bolts. Tighten the engine mount bracket bolts to 75 N.m (55 lb ft). 4. Position the engine mount side bracket to the engine, if removed and equipped. (right side shown, left side similar). 5. Install the engine mount side bracket bolts. Tighten the engine mount side bracket bolts to 50 N.m (37 lb ft). 6. Install the engine mount. (right side shown, left side similar). 7. Install the engine mount bolts. Tighten the engine mount bolts to 50 N.m (37 lb ft). 8. Lower the engine. 9. Install the oil pan skid plate and bolts. Tighten the oil pan skid plate bolts to 20 N.m (15 lb ft). 10. Lower the vehicle. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Multiple Junction Connector: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 20179 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Page 11023 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 7295 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 21562 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 8433 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 22493 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 22213 Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab with A68) Rear Seat Back Cushion Cover and Pad Replacement (Crew Cab with A68) Page 7507 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 15331 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Remove the knock sensor heat shield bolt and shield. Page 10713 8. Open the axle vent hose clip on the fuel fill pipe bracket. 9. Remove the rear axle vent hose from the clip. 10. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (2) from the fuel fill pipe recirculation line. 11. Loosen the fuel tank fill pipe clamp (1) at the fuel tank. 12. Remove the fuel tank fill pipe. 13. Cap the opening on the fuel tank in order to prevent possible system contamination. Installation Procedure Page 20325 The identification tag on the rear half of the transfer case provides the information shown. Disclaimer Page 24608 10. Remove the windshield washer solvent cap. 11. Remove the auxiliary battery tray, if equipped. 12. Remove the upper windshield washer container bolt from under the auxiliary battery tray, if equipped. Important: Remove the washer container from the underside of the vehicle through the wheelhouse opening. 13. Remove the upper windshield washer solvent container bolts. 14. Remove the windshield washer solvent container assembly (2). Installation Procedure 1. Transfer washer pumps and level indicator to the new washer solvent container. Page 23208 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 8743 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Fog Lamp Switch Replacement (with RPO SLT) Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (with RPO SLT) Fog Lamp Switch Replacement (with RPO SLT) Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Page 2719 Page 21801 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. HVAC - Automatic Low Pressure Sensor / Switch: Locations HVAC - Automatic HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 23589 View of the connector when released from the component. View of another type of Micro 64 connector. Page 4224 Customer TPMS Information TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Rear Seat Latch Replacement (Extended Cab with AM7) Seat Latch: Service and Repair Rear Seat Latch Replacement (Extended Cab with AM7) Rear Seat Latch Replacement (Extended Cab with AM7) 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Input Speed Sensor (ISS) Harness Page 14071 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). Tighten the bolts to 10 N.m (89 lb in). Ball Check Valves 5. Install the 7 checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Page 24111 Disclaimer Page 2927 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 23124 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 11520 Page 11809 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 10580 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 11367 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 7325 Page 596 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 11719 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 10887 * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 23232 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Brakes - Aftermarket Trailer Brake Controllers Trailer Brake Control Module: All Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 14698 Shift Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 21397 Front Floor Console Replacement (with RPO SLT) Front Floor Console Replacement (with RPO SLT) Page 12383 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: * The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. * Apply the park brake. * The engine must start in the park (P) or neutral (N) positions only. * Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 14778 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 13216 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Page 12817 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 14053 Valve Body: Diagrams Allison - Automatic Transmission Control Valve Body Assembly Disassembled Views Control Valve Body Assembly 1 - Control Valve Body Assembly 2 - Shift Valve Body Assembly 3 - Separator Plate 4 - Main Valve Body Assembly 5 - Transmission Fluid Pressure (TFP) Switch 6 - Main Valve Body Assembly Bolt, M6 x 10 x 50, Flanged Head (23) 7 - Reverse Signal Pipe 8 - Reverse Signal Pipe Bolt, M6 x 10 x 50, Flanged Head Service and Repair Backup Light Bulb: Service and Repair Backup Lamp Bulb Replacement (Chevrolet) Page 12526 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 1816 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Service and Repair Expansion Block/Orifice Tube: Service and Repair Expansion (Orifice) Tube Replacement Page 24523 to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Owner Letter Owner Letter September 2008 Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2006-2008 model year Buick Lucerne; Cadillac DTS; HUMMER H2 vehicles; 2007-2008 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK vehicles; and 2008 model year Buick Enclave vehicles equipped with a heated washer fluid system. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 08048. - Schedule an appointment with your GM dealer/retailer on or after November 1, 2008. Why is your vehicle being recalled? A short circuit on the printed circuit board for the washer fluid heater may overheat the control-circuit ground wire. This may cause other electrical features to malfunction, create an odor, or cause smoke. In rare cases, it may cause a fire. What will we do? When parts are available, your dealer/retailer will install a wire harness with an in-line fuse. This service will be performed for you at no charge. We are currently working with our suppliers, and parts should be available on or after November 1, 2008. If your vehicle is within the New Vehicle Limited Warranty your dealer/retailer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership/facility for this repair. Please refer to your Owner Manual and your dealer/retailer for details on courtesy transportation. What should you do? On or after November 1, 2008, you should contact your GM dealer/retailer to arrange a service appointment. Bring the customer reply form with you when you visit your dealer/retailer. The form identifies the repairs required. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us. If your vehicle experiences any of the symptoms described earlier in this letter, please bring your vehicle to the dealer. Do you have questions? If you have questions or concerns that your dealer/retailer is unable to resolve, please contact the appropriate GM Customer Assistance Center. More information about this recall can be found at the Owner Center at MyGMLink, http://www.gm.com/recall. If after contacting your dealer/retailer and the Customer Assistance Center, you are still not satisfied we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Page 9963 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Notice: Refer to Fastener Notice. 4. Install the VSS bolt (2). Tighten the bolt to 11 N.m (97 lb in). Page 7328 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 4880 Page 21970 4. Turn the sunshade cam (2) until it is aligned with the bracket (3) notch. 5. Install the sunshade. 6. Remove the suitable tool (1) from the sunshade cam locking hole (2). 7. Ensure that the sunshade cam (2) is fully seated in the bracket (3) and the sunshade slides smoothly. 8. Install the sunroof window. 9. Verify the operation of the sunshade. Page 5018 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 23184 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 9892 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 13480 Transmission Position Switch/Sensor: Service and Repair Allison - Automatic Transmission Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Page 23853 Page 11975 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 17280 For vehicles repaired under warranty, use the table. Disclaimer Page 24698 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 21895 OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Page 11883 Page 9753 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10961 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 21831 View of the connector when released from the component. View of another type of Micro 64 connector. Page 5219 Important: Insert the 3 lower tabs into the radiator support flange. Keeping the shroud parallel to the radiator will ensure the correct installation of the lower tabs. 1. Install the cooling fan and shroud. Notice: Refer to Fastener Notice. 2. Install the cooling fan shroud bolts. Tighten the bolts to 9 N.m (80 lb in). 3. If equipped, install the cooler lines to the clip and close the clip. Page 273 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 8440 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 3108 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 3974 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 16109 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 22442 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 9146 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 17434 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 23702 Hazard Flasher Relay: Diagrams Wrecker Relay X1 (5X7) Power and Grounding Connector End Views Wrecker Relay X1 (5X7) Page 19632 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 4995 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 19599 Page 1796 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6196 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 19810 Page 18067 Disclaimer Electrical - 'No Trailer Connected' Message On DIC Trailer Brake Control Module: All Technical Service Bulletins Electrical - 'No Trailer Connected' Message On DIC TECHNICAL Bulletin No.: 09-05-22-004 Date: November 05, 2009 Subject: No "Trailer Connected" Message on Driver Information Center (DIC) at Startup When Trailer is Connected (Reprogram ITBCM) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Equipped with Integrated Trailer Brake (RPO JL1) Condition Some customers may comment that when they connect their trailer, with the engine off, and after they start the engine, the Trailer Connected message is not displayed on the DIC. With the engine running, if the trailer connector is cycled, the vehicle will detect the trailer and display Trailer Connected. This concern should only affect trailers equipped with trailer brakes on a single axle. Cause The trailer brake control system is only compatible with trailers equipped with electric trailer brakes. The system will not work or detect trailers equipped with any other types of brakes such as surge, air or electric-over-hydraulic trailer brake systems. When a trailer is connected, the Trailer Brake Control Module (TBCM) performs a test to determine if the trailer is equipped with electric trailer brakes. If the trailer wiring or electric trailer brake magnets have additional resistance (caused by poor connections, corrosion, improper splices, etc.), the TBCM may not be able to detect the trailer. Correction A revised calibration has been developed to address these issues. Reprogram the Integrated Trailer Brake Control Module (ITBCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Refer to Trailer Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 16064 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Service and Repair Power Take-Off Switch: Service and Repair Power Take-Off Switch Replacement Page 8891 Engine Control Module: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 8115 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 16036 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 7945 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 16094 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 8397 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 14214 3. Grip the rib on the axle shaft flange with a locking pliers. Twist the axle shaft flange in order to start the axle shaft removal. 4. Remove the axle shaft from the tube. 5. Remove the gasket. 6. Clean the axle shaft flange and the outside face of the hub assembly. Installation Procedure 1. Install the gasket onto the axle shaft. 2. Install the gasket and the axle shaft into the axle tube. 1. Ensure the shaft splines mesh into the differential side gear. 2. Align the holes in the axle flange and the gasket with the holes in the hub. Notice: Refer to Fastener Notice. 3. Install the axle flange bolts. * For the 10.5 inch axle, tighten the rear axle flange bolts to 156 N.m (115 lb ft). * For the 11.5 inch axle, tighten the rear axle flange bolts to 185 N.m (136 lb ft). 4. Inspect and add axle lubricant to the axle housing, if necessary. Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Rear Axle Hub, Bearing, Cup, and/or Seal Replacement Tools Required * J 8092 Universal Driver Handle - 3/4 inch - 10 * J 2222-C Wheel Bearing Nut Wrench * J 24426 Wheel Bearing Race Installer - Outer * J 24427 Wheel Bearing Race Installer - Inner * J 44419 Hub Outer Bearing Race Installer * J 44420 Differential Bearing and Hub Seal Installer Removal Procedure Important: The wheel hub seal must be replaced anytime the wheel hub assembly is removed from the axle housing. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper bracket. It is not necessary to remove the brake caliper from the bracket. 4. Remove the axle shaft. Page 19494 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Page 3331 12. Inspect the transmission fluid pressure manual valve position switch assembly for the following conditions: * Damage * Debris * Damaged or missing O-rings * Cracked connector * Loose electrical terminals * Poor terminal retention 13. Remove the manual detent spring bolt. 14. Remove the manual detent spring. 15. Inspect the manual detent spring for cracks or damage. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 16. Remove the remaining valve body bolts. Page 5917 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12763 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. Specifications Thermostat: Specifications The thermostat should begin to open .................................................................................................. ............................................................. 87°C (188°F). The thermostat should be fully open .............. ................................................................................................................................................... 97°C (206°F) Page 5044 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10446 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 7249 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 22463 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 11108 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 8091 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14735 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 316 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 12651 Vehicle Zoning Strategy Truck Zoning Page 8555 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 4245 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 14384 6. Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 7. Road test the vehicle and verify that the noise is gone. Note Do Not replace the slip yoke unless the cleaning and lubrication procedure is ineffective. 8. If the vehicle has a repeat concern after lubricating the slip yoke splines, it may be necessary to replace the propeller shaft slip yoke with a new nickel-plated slip yoke. Replace the Propeller Shaft Slip Yoke 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. Important Some U-joints are fastened with nylon injection clips. If so, Do Not reuse the U-joint. Replace with GM P/N 12479126 U-Joint kit. 2. Replace the propeller shaft slip yoke with a new nickel-plated slip yoke. Refer to Propeller Shaft Slip Yoke Replacement in SI. 3. Install the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 23416 Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE MONITOR SYSTEM The Tire Pressure Monitor System (TPMS) uses radio and sensor technology to check tire pressure levels. If your vehicle has this feature, sensors are mounted on each tire and wheel assembly, except the spare tire. The TPMS sensors monitor the air pressure in your vehicle's tires and transmit tire pressure readings to a receiver located in the vehicle. The TPMS is designed to alert the driver, if a low tire pressure condition exists. If your vehicle has the Driver Information Center (DIC), the driver may also check tire pressure levels using the DIC. When a low tire pressure condition is detected, the TPMS will illuminate the low tire pressure warning symbol located on the instrument panel cluster. If your vehicle has the DIC feature, a message to check the pressure in a specific tire will also appear on the DIC display. The low tire pressure warning symbol on the instrument panel cluster and the "CHECK TIRE PRESSURE" warning message on the DIC display will appear at each ignition cycle until the tires are inflated to the correct inflation pressure. You may notice, during cooler weather conditions, that the tire pressure monitor light, located on the instrument panel cluster, and the "CHECK TIRE PRESSURE" message will appear when the vehicle is first started and then turn off as you start to drive the vehicle. This could be an early indicator that the tire pressures are getting low and need to be inflated to the proper pressure. Each tire, including the spare (if provided), should be checked monthly when cold and inflated to the inflation pressure recommended by the vehicle manufacturer on the vehicle placard or tire inflation pressure label. (If your vehicle has tires of a different size than the size indicated on the vehicle placard or tire inflation pressure label, you should determine the proper tire inflation pressure for those tires.) As an added safety feature, your vehicle has been equipped with a tire pressure monitoring system (TPMS) that illuminates a low tire pressure telltale when one or more of your tires is significantly under-inflated. Accordingly, when the low tire pressure telltale illuminates, you should stop and check your tires as soon as possible, and inflate them to the proper pressure. Driving on a significantly under-inflated tire causes the tire to overheat and can lead to tire failure. Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle's handling and stopping ability. Please note that the TPMS is not a substitute for proper tire maintenance, and it is the driver's responsibility to maintain correct tire pressure, even if under-inflation has not reached the level to trigger illumination of the TPMS low tire pressure telltale. Your vehicle has also been equipped with a TPMS malfunction indicator to indicate when the system is not operating properly. The TPMS malfunction indicator is combined with the low tire pressure telltale. When the system detects a malfunction, the telltale will flash for approximately one minute and then remain continuously illuminated. This sequence will continue upon subsequent vehicle start-ups as long as the malfunction exists. When the malfunction indicator is illuminated, the system may not be able to detect or signal low tire pressure as intended. TPMS malfunctions may occur for a variety of reasons, including the installation of replacement or alternate tires or wheels on the vehicle that prevent the TPMS from functioning properly. Always check the TPMS malfunction telltale after replacing one or more tires or wheels on your vehicle to ensure that the replacement or alternate tires and wheels allow the TPMS to continue to function properly. The "CHECK TIRE PRESSURE" warning message and low tire pressure light (telltale) will come on each time the vehicle is started until the tires are inflated to the correct inflation pressure. The Tire and Loading Information label (tire information placard) shows the size of your vehicle's original tires and the correct inflation pressure for your vehicle's tires when they are cold. Your vehicle's TPMS can alert you about a low tire pressure condition but it does not replace normal tire maintenance. NOTICE: Do not use a tire sealant if your vehicle has Tire Pressure Monitors. The liquid sealant can damage the tire pressure monitor sensors. Page 23812 10. Twist the end of circuit 3040 together with circuit 240. Connect the circuits from the side of the circuit that does not have a terminal. Important: Apply heat to sleeve using a hot air gun or Ultratorch. Apply heat to the center of the sleeve and continue heating for a minimum of 30 seconds. Once the glue starts to melt, slowly rotate the sleeve while applying heat evenly until hot glue is visible outside the sleeve. 11. Using a BLUE colored crimp and seal splice sleeve PN 12089190, crimp the 240/3040 end to the 3040 end. Refer to Splicing Copper Wire Using Splice sleeves in SI, if required. 12. Re-apply tape (1) to the harness. 13. Plug the 40-way connector X1 back into the backside of the LBEC. 14. Verify that there is power to the beacon switch by activating the switch. If the beacon switch light indicator illuminates when the switch is in the ON position and turns off when the switch is in the OFF position, the repair has been performed correctly. 15. Install the instrument panel (I/P) knee bolster. Refer to Knee Bolster Replacement in SI. 16. Install the park brake release handle. Refer to Park Brake Release Handle Assembly Replacement in SI. Claim Information For vehicles repaired under this service update, use the table. Page 1931 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 23083 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 7055 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Accessories - Universal Home Remote Diagnostics Garage Door Opener Transmitter: Technical Service Bulletins Accessories - Universal Home Remote Diagnostics Bulletin No.: 07-08-97-001 Date: September 28, 2007 INFORMATION Subject: Diagnostic Information For a Universal Home Remote (UHR) System That Is Not Operating and J 41450 HomeLink Tester Is Not Communicating With UHR Module Models: 2008 Buick Lucerne 2007-2008 Cadillac CTS, Escalade Models, SRX, STS, XLR 2008 Cadillac DTS 2007-2008 Chevrolet Avalanche, Corvette, Impala, Malibu, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon Models 2008 HUMMER H2, H2 SUT 2007-2008 Saturn AURA with Universal Home Remote System (RPO UG1) The purpose of this bulletin is to provide dealership personnel with diagnostic information and procedures for the new Universal Home Remote (UHR) system that is now available on certain 2007 and all 2008 model year vehicles listed above. When diagnosing a UHR system that is not operating, technicians may also find that the J 41540 HomeLink Tester is not communicating with the UHR module. The new UHR module does not have the software capability to communicate with the J 41540 HomeLink Tester. Technicians should first refer to PIT4073A for overall programming information. Next, contact Lear Car2U Hot Line for assistance prior to any repair. Please have the customer's original comments and your preliminary findings before making the call. Production Dates For Vehicles With Updated UHR Diagnostic Software Corvette, XLR, SRX and Model Year 2007 CTS Vehicles built after November 2006 Tahoe, Yukon/XL/Denali/XLDenali, Escalade/EXT/ESC, Avalanche, Suburban Vehicles built after March 2007 Sierra, Silverado Vehicles built after March 2007 Malibu, AURA, Impala, STS Vehicles built after April 2007 Lucerne, DTS, H2 software change incorporated for Model Year 2008 Disclaimer Locations Accelerator Pedal Position Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 1604 Ambient Temperature Sensor / Switch HVAC: Diagrams HVAC Connector End Views Ambient Air Temperature Sensor - HVAC Page 18750 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular/Extended Cab -10 Series) Page 21633 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 21807 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 9860 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 9270 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 22138 Power Seat Motor: Diagrams Power Seat Connector End Views Seat Adjuster Assembly - Driver (AG1 -AN3) Seat Adjuster Assembly - Driver X1 (AN3) Page 23598 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 18917 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Page 3025 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 17001 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 6186 View of the connector when released from the component. View of another type of Micro 64 connector. Page 12992 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14267 7. Align the hole in the pinion shaft with the bolt hole in the differential case. Notice: Refer to Fastener Notice. 8. Install the new pinion shaft locking bolt. * For the 8.6 inch axle, tighten the pinion shaft locking bolt to 36 N.m (27 lb ft). * For the 9.5/9.6LD inch axle, tighten the pinion shaft locking bolt to 50 N.m (37 lb ft). 9. Install the rear cover and the gasket. 10. Install the brake caliper. 11. Install the tire and wheel assembly. 12. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. 13. Lower the vehicle. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 4421 * When lifting or jacking a vehicle, be certain that the lift pads do not contact the exhaust system, brake pipes, cables, HVAC lines, wiring harnesses, fuel lines, or underbody. Such contact may result in damage or unsatisfactory vehicle performance. * When using a frame-contact hoist, only place the pads on flat surfaces. Do not place pads within 50 mm (2 in) of any radius. * Before lifting the vehicle, verify that the vehicle loads are secure and equally distributed. * When major components are removed from the vehicle when supported on a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and secure the vehicle frame to the hoist pads nearest the component to be removed. Vehicle Jacking * Park the vehicle on a clean, hard, level surface before jacking the vehicle. * Any time you lift the vehicle on one end, chock the wheels at the opposite end. * Use jack stands in order to provide support. * When supporting the vehicle using jack stands, place the jack stands under the side rails or the axle. * When lifting under the rear differential, do not allow the jack pad to contact the rear stabilizer bar or mounting hardware. Page 23956 Page 15337 Front Brake Caliper Replacement (JH6, JH7) Front Brake Caliper Replacement (JH6, JH7) Page 6864 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 9750 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 5822 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Diagrams Steering Mounted Controls Assembly: Diagrams Secondary/Configurable Control Connector End Views Steering Wheel Control Switch Assembly - Left (K34/KA9) Steering Wheel Control Switch Assembly - Right (UK3) Page 10908 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 16484 X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (AZ3/D07 +UQ3) Page 22394 Seat Heater: Locations Heated/Cooled Seat Component Views Memory/Heated Seat Switch 1 - Outside Rearview Mirror (OSRVM) - Driver 2 - Memory/Heated Seat Switch (AN3) Passenger Heated Seat Switch Page 7263 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Locations Battery Current Sensor: Locations Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor Page 24753 Page 4876 Page 7571 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 3914 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 15666 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the negative battery cable. 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 8548 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 9601 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 13791 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Testing and Inspection Idler Arm: Testing and Inspection Idler Arm Inspection Tools Required * J 35999 Spring Scale * J 42640 Steering Column Anti-Rotation Pin * J 45101 Hub and Wheel Runout Gage 1. Raise the vehicle on a hoist and support it with jackstands. Refer to Vehicle Lifting. Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. 2. Position the wheels straight-ahead and install anti-rotation pin J 42640. 3. Install runout gauge J 45101 between the idler arm and the vehicle frame. Ensure the runout gage is at zero before taking the measurement. 4. Place scale J 35999 near the relay rod end of the idler arm. Page 24169 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 6213 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 15526 Vacuum Brake Booster: Service and Repair Power Vacuum Brake Booster Replacement (Adjustable Pedals) Power Vacuum Brake Booster Replacement (Adjustable Pedals) Page 14702 Page 10196 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 1167 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 16161 Fuse Block: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 22892 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Crew Cab) Sunroof Window Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the sunroof window. 2. Carefully remove the sunroof window weatherstrip from the perimeter of the sunroof window. Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window to the sunroof module assembly. 3. Ensure that the sunroof does not have any air or waterleaks. Page 3311 Tire Pressure Sensor: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 15684 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Page 14770 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 6133 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 7563 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12427 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 2828 Page 4767 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Page 8154 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 5663 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 16416 X220 Inline Harness Connector End Views X220 Brake Clutch Harness to Chassis Harness (JL1) X224 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0/5X7) Page 4795 4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 5. Install the air cleaner outlet resonator to the MAT/IAT sensor. 6. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). Page 5557 6. Loosely position the Y-pipe support braces w/integral U-bolt clamps (LH and RH) to the underside of the transmission rear mount and the crossover pipe as shown. The top ends of the braces attach to the underside of the transmission rear mount. The bottom ends of the braces attach to the crossover pipe using the integral U-bolt clamps. The braces support the LH leg of the Y-pipe where it crosses over the vehicle to meet the Y-pipe collector. 7. Install the two nuts to the transmission rear mount and the two nuts to the U-bolt clamps. Tighten - Tighten the new transmission mount nuts to 25 Nm (18 lb ft). - Tighten the two U-bolt clamps to 30 Nm (22 lb ft). 8. Lower the vehicle. 9. Verify that the condition has been fixed. Parts Information -- Kit P/N 15076982 includes a flex coupler, two support brace rods w/integral U-bolt pipe clamps, two U-bolt pipe clamps (for use with flex coupler) and two new transmission mount studs w/fasteners. - Kit P/N 15076990 includes a flex coupler and two U-bolt pipe clamps. Warranty Information For vehicles repaired under warranty, use: For locally obtained flex coupling, submit the amount into the NET amount field. Disclaimer Page 1158 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: Customer Interest Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 7403 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 4056 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 19093 29. Connect the deployment harness to the seat belt pretensioner connector. 30. Route the deployment harness out of the passenger's side of the vehicle. 31. Completely cover the windshield and the front door openings with a drop cloth. 32. Deploy each deployment loop one at a time. 33. Stretch out all of the deployment harness wires on the left and right side of the vehicle to their full length. 34. Place a power source, 12 volt minimum/2 amp minimum, such as a vehicle battery, near the shorted end of the harnesses. 35. Separate one set of wires and touch the wire ends to the power source in order to deploy the seat belt pretensioners. 36. Disconnect the deployment harness from the power source and twist the wire ends together. 37. Continue the same process with the remaining deployment harnesses that are available. 38. Remove the drop cloth from the vehicle. 39. Disconnect all harnesses from the vehicle. 40. Discard the harnesses. 41. Scrap the vehicle in the same manner as a non-SIR equipped vehicle. 42. If one or more of the seat belt pretensioners did not deploy, perform the following steps to remove the undeployed seat belt pretensioner from the vehicle, Refer to Seat Belt Retractor Pretensioner Replacement - Front (Regular Cab) Seat Belt Retractor Pretensioner Replacement - Front (Extended Cab) Seat Belt Retractor Pretensioner Replacement - Front (Crew Cab). 43. Call the Technical Assistance Group for further assistance. Page 11905 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14589 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 17043 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 22420 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 10016 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 2831 Vehicle Zoning Strategy Truck Zoning SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Classification Module - Air Bag: Customer Interest SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 20045 Page 3897 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 2628 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 6358 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 11189 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9708 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 14329 Seals and Gaskets: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) Tools Required * J 8092 Universal Driver Handle-3/4 in - 10 * J 21128 Axle Pinion Oil Seal Installer * J 23690 Axle Shaft Bearing Installer * J 2619-01 Slide Hammer * J 44685 Rear Axle Seal and Bearing Remover Removal Procedure 1. Remove the axle shaft. 2. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (1) and the J 2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Page 6736 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 10026 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 7336 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Body - Power Sliding Rear Window Inoperative Back Window Regulator: All Technical Service Bulletins Body - Power Sliding Rear Window Inoperative Bulletin No.: 07-08-48-002 Date: March 09, 2007 TECHNICAL Subject: Power Rear Sliding Window (RPO A48) Inoperative, Will Not Open, and/or Will Not Shut (Replace Rear Window Regulator) Models: 2007 Chevrolet Silverado (New Style) 2007 GMC Sierra (New Style) with Power Rear Sliding Window (RPO A48) Condition Some customers may comment that the power rear sliding window is inoperative, will not open, and/or will not shut. Cause This condition may be caused by the cable ball separating from the cable end in either side of the center glass carrier. Correction Do NOT replace the entire rear window assembly. Replace only the rear window regulator, P/N 25782000. Refer to Rear Sliding Window Regulator Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3785 2. Install the new rear axle housing cover bolts (1). Tighten the bolts to 40 N.m (30 lb ft). 3. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. 4. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 5. Lower the vehicle. Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the rear axle fill plug. 3. Remove the rear axle drain plug. 4. Drain the lubricant into a suitable container. 5. Inspect the drain plug for excessive metal particle accumulation. This accumulation is symptomatic of extreme wear. Page 14749 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 5908 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 8416 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Interior - Sun Visor Fails to Stay In Up Position Sun Visor: All Technical Service Bulletins Interior - Sun Visor Fails to Stay In Up Position TECHNICAL Bulletin No.: 09-08-110-013A Date: April 18, 2011 Subject: Sunshade (Sun Visor) Fails to Stay In Position (Re-seat Detent Spring) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL Supercede: This bulletin is being revised to include the 2012 model year. Please discard Corporate Bulletin Number 09-08-110-013 (Section 08 - Body and Accessories). Condition Some customers may comment that the front sunshade (sun visor) doesn't stay in position tightly against the headliner when in the up position and clipped into the center mount. Cause The condition may be caused by the sunshade being over extended (forced) along the slide on rod to the end of its travel. This over extension can cause the detent spring to be pulled off of the flat on the slide on rod and can cause the detent function to be inoperative. Correction In many cases, the detent spring can be re-seated into the correct position. Use the following procedure to correct the condition. 1. Position the sunshade in the forward position and engage the sunshade into the center clip. Page 20884 Caution Exceeding the recommended screw torque of 6 Nm (53 lb in) could result in the thread insert pulling out of the handle base, as shown in the graphic above. Replace the affected chrome outside door handle. Refer to Front Side Door Outside Handle Replacement, Rear Side Door Outside Handle Replacement, or Rear Side Door Outside Handle Replacement (Crew Cab) in SI. Parts Information Acrysol(TM) is available from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Technical Service Bulletin # 09-08-64-023 Date: 090603 Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can Navigation Radio - Various Noises Explained Navigation System: All Technical Service Bulletins Navigation Radio - Various Noises Explained INFORMATION Bulletin No.: 06-08-44-034E Date: February 11, 2011 Subject: Information on Noise Sources from Navigation Radio - CD/DVD Disc Accessing Noise from Radio Fan, for Cooling, Disc Accessing Noise for Navigation Operation or NAV Traffic Information Models: 2008-2011 Buick Enclave 2007-2009 Cadillac SRX 2007-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009-2011 Chevrolet Traverse 2007-2011 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2007-2009 HUMMER H2 2007-2010 Saturn OUTLOOK Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 06-08-44-034D (Section 08 - Body and Accessories). Some customers may comment that there are unusual fan type noises coming from the navigation radio. Additionally, the customer may comment on radio noise coming from the CD/DVD or MAP disc mechanisms when CDs/DVDs or MAP discs are present in the CD mechanisms. Some customers have mentioned that radio noise is present when the customer enters the vehicle or that the noise continues after they shut the vehicle off and open the door to leave the vehicle. This noise has been described as a fan sound or hearing a disc spinning. Source of fan sound - It is normal for the radio fan to run when the vehicle is turned on and for up to three minutes after the vehicle has been turned off and the driver's door has been opened or closed. Disc spinning sound - This is a normal operational sound. This is caused by the map disc spinning behind the tilt screen. It is a normal operation after the RKE is used to unlock the vehicle or when the driver's door has been opened. This noise will also be heard during vehicle operation and up to three minutes after the vehicle has been turned off and driver's door has been opened and closed. MAP Disc Accessing "ZIP" sound - As the Navigation Radio accesses the MAP Disc, the customer may describe frequent "zip" type noises. This noise is caused by the CD Read Lens moving across the disc to access needed data for proper MAP display. To determine if the source of the noise is from accessing the MAP Disc, remove the MAP Disc to determine if the noise continues. With the addition of the Real Time NAV Traffic Feature, the MAP CD may be accessed to a greater extent thus resulting in additional MAP Drive noise. Inform the customer about these noises. If the customer believes the noise is not normal, compare the condition to a like vehicle with identical settings to determine if there is a noticeable difference. Do not replace the radio as the described conditions are normal operating characteristics. Disclaimer Page 11964 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 11399 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. Circuit/System Verification Ignition ON, the MIL should turn ON and OFF when commanded with a scan tool. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the instrument panel cluster (IPC). 2. Ignition ON, verify that a test lamp illuminates between the ignition circuit and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 3. Connect a test lamp between the control circuit and the ignition circuit. 4. Command the MIL ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, replace the IPC. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Refer to Programming and Relearning for Control Module setup and programming. See: Testing and Inspection/Programming and Relearning * Instrument Cluster Replacement (without RPO SLT) Instrument Cluster Replacement (with RPO SLT) Page 16464 X211 Instrument Panel Harness (Y91) Or I/P Extension Harness (-Y91) To Console Harness (Y91/UQA/D07) (Pin A1 To C6) Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Electrical Symbols Electrical Symbols Vehicle - Recreational (Dinghy) Towing Information Towing Information: Technical Service Bulletins Vehicle - Recreational (Dinghy) Towing Information Bulletin No.: 00-00-89-008F Date: July 28, 2006 INFORMATION Subject: Recreational (Dinghy) Towing Page 9452 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 6118 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 5121 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Allison - Automatic Transmission Transmission Mode Switch: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Transmission Internal Mode Switch Page 8476 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 17081 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 6122 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 22117 Memory Seat Module X6 (AN3) Page 2905 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 5077 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 2891 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 17067 View of the connector when released from the component. View of another type of Micro 64 connector. Diagrams Rain Sensor: Diagrams Wiper/Washer Connector End Views Outside Moisture Sensor (CE1) Locations Oxygen Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 1928 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 16681 Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: All Technical Service Bulletins Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6805 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 22922 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 12707 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 463 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 11586 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 22726 Tailgate Hinge: Service and Repair Endgate Lower Hinge Replacement - Body Side Endgate Lower Hinge Replacement - Body Side Page 2402 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 19348 Page 20677 Page 14901 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Interior - Front Power Seat Adjust/Memory Inoperative Power Seat Switch: All Technical Service Bulletins Interior - Front Power Seat Adjust/Memory Inoperative Bulletin No.: 06-08-50-012 Date: October 06, 2006 TECHNICAL Subject: Front Driver or Passenger Power Seat Adjust Functions Inoperative and/or Driver Seat Memory Inoperative (Check Power Seat Switch Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (New Style), Suburban, Tahoe 2007 GMC Sierra (New Style), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the front driver or passenger power seat adjust functions are inoperative. They may also comment that the driver seat memory is inoperative. Cause The cause of this condition may be due to the power seat switch connector not being fully seated. Correction Remove the front seat cushion outer trim panel following the replacement procedure in SI. Verify that the power seat switch connector is fully seated. Reseat the connector and test the seat functions. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4569 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Page 3993 Page 1620 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Right Side Air Temperature Sensor Replacement - Lower Right Side Page 891 Auxiliary Body Control Module (XBCM) X2 (Export) Page 2646 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 7275 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2447 Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (3). Tighten the sensor to 42 N.m (31 lb ft). 3. Install the HO2S pigtail electrical connector clip to the engine wiring harness clip (3). Page 21194 Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Page 4905 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 23627 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 22416 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 2202 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 11513 Page 10638 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion A/T - Fluid Leak From Bell Housing Area Seals and Gaskets: Customer Interest A/T - Fluid Leak From Bell Housing Area TECHNICAL Bulletin No.: 08-07-30-023 Date: May 08, 2008 Subject: 4L60-E/4L65-E/4L70‐E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Replace Torque Converter Hub-to-Oil Pump Seal Assembly) Models: 2007-2008 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe, TrailBlazer 2007-2008 GMC Envoy, Savana, Sierra, Yukon, Yukon XL 2007-2008 HUMMER H2 2007-2008 Saab 9-7X with 4L60-E, 4L65-E or 4L70‐E Automatic Transmission (RPOs M30, M32 or M70) and 4.8L, 5.3L or 6.0L V8 Engine Attention: This bulletin applies to vehicles built prior to December 2007. Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. Cause Investigation of 2007 transmissions has shown wear of the torque converter hub-to-pump seal (243, illustrated in the Oil Pump Disassembled View in SI). Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If the leak is coming from the bell housing replace the torque converter seal. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 5133 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 8190 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 18669 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Accident Damage Inspection * Vehicles involved in accidents which result in the following conditions may also have a damaged or misaligned steering column: - Frame damage - Major body or sheet metal damage - Where the steering column has been impacted - Where supplemental inflatable restraint systems deployed * Inspect the capsules on the steering column bracket assembly. All capsules must be securely seated in the bracket slots and checked for any loose conditions when pushed or pulled by hand. If not, the bracket should be replaced if bolted to the jacket assembly. If the bracket is welded to the jacket assembly replace the jacket assembly. * Inspect for jacket assembly collapse by measuring the distance from the steering column support bracket mounting plate (1) to the lower edge of the jacket lower bracket (2). Replace the jacket assembly if the measured dimensions are less than 286 mm. Page 10615 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 978 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 9041 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 5871 Page 22506 Seat Heater: Connector Views Heated/Cooled Seat Connector End Views Heated Seat Element - Driver Back Heated Seat Element - Driver Cushion 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission: * The torque converter clutch solenoid (1) * The pressure control solenoid (2) * The internal wiring harness (3) * The 2-3 shift solenoid (4) * The 1-2 shift solenoid (5) * The transmission fluid pressure manual valve position switch (6) * The 3-2 shift solenoid (7) * The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wiring harness electrical connectors from the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) Page 3868 Junction Block - Left I/P, Label Junction Block - Left I/P, Device Usage Right I/P Junction Block Page 14397 Drive/Propeller Shaft: Service and Repair One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement Removal Procedure Important: Observe and accurately reference mark all driveline components relative to the propeller shaft and axles before disassembly. These components include the propeller shafts, the drive axles, the pinion flanges, the output shafts, etc. All components must be reassembled in the exact relationship to each other as they were when removed. In addition, published specifications and torque values, as well as any measurements made prior to disassembly must be followed. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Reference mark the propeller shaft to the rear axle pinion yoke. 3. Reference mark the propeller shaft to the transmission or transfer case. 4. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (3). Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 5. Slide the propeller shaft forward in order to disconnect the propeller shaft from the rear axle pinion yoke. 6. Slide the propeller shaft rearward in order to disconnect the propeller shaft from the transmission or transfer case. Page 13579 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12604 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 9814 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Notice: Refer to Fastener Notice. 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 N.m (92 lb in). 5. Install the control valve assembly. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 3374 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 8865 For vehicles repaired under warranty use, the table. Disclaimer Page 8419 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Locations Exterior Lighting Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 3984 Page 15400 Page 16916 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 8474 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 6834 Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the vehicle speed sensor (VSS) electrical connector (2). 3. Remove the VSS bolt (2). 4. Remove the VSS (1). 5. Remove the O-ring seal (3). Installation Procedure 1. Install the O-ring seal (3) onto the VSS (1). 2. Coat the O-ring seal (3) with a thin film of transmission fluid. 3. Install the VSS (1). Notice: Refer to Fastener Notice. 4. Install the VSS bolt (2). Tighten the bolt to 11 N.m (97 lb in). Page 7615 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 23647 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Locations Alarm Module: Locations Immobilizer Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 10110 12. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 13. Install the EVAP canister vent solenoid pipe clip (2) to the chassis EVAP line. 14. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 15. Install the fuel line clip (1) to the bracket on the automatic transmission. Page 15195 corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). Page 9834 Sunroof Water Gutter Replacement (Extended Cab) Sunroof / Moonroof Drain: Service and Repair Sunroof Water Gutter Replacement (Extended Cab) Sunroof Water Gutter Replacement (Extended Cab) Removal Procedure Important: Tape off the perimeter of the sunroof window opening before removing the sunroof module to prevent scratching. 1. Remove the air deflector. 2. Set the sunroof window to be in the open position of a minimum of 25 mm (1 in). Important: It is only necessary to lower the headliner. Only do those steps in headlinder replacement that will lower the headlinder enough to grain access. 3. Remove the sunroof module assembly. 4. Remove the screws (1) from the water gutter (2). TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 7592 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 2902 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 13460 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 113 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Page 9848 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 16963 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 12429 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 17374 X304 Inline Harness Connector End Views X304 Headliner Harness to Overhead Console Harness Locations Trunk / Liftgate Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 20695 Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information Page 8151 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Locations Driver/Vehicle Information Display: Locations Displays and Gages Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 9457 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5662 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 4611 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 6675 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 15827 5. Remove the starter motor bolts. 6. Remove the starter solenoid cable lead nut (1). 7. Remove the starter solenoid cable lead (2) from the starter. A/C - Compressor/Serpentine Belt Noise Drive Belt: All Technical Service Bulletins A/C - Compressor/Serpentine Belt Noise TECHNICAL Bulletin No.: 07-01-38-010A Date: October 06, 2009 Subject: Air Conditioning (A/C) Compressor and/or Serpentine Belt Noise at Vehicle Start-up (Reprogram Powertrain Control Module (PCM)) Models: 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon Models Equipped With Air Conditioning (RPOs CJ2 or CJ3) Supercede: This bulletin is being revised to update the Condition and Correction information. Please discard Corporate Bulletin Number 07-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on air conditioning (A/C) compressor slugging and/or serpentine belt or pulley rattle noise at vehicle start-up in warmer outside ambient temperature conditions. Others may describe the noise as a belt chirp or as a thumping/grinding noise coming from the A/C compressor at vehicle start-up. Cause This condition may be caused by the A/C compressor trying to move liquid refrigerant through the system. Correction - A revised PCM calibration has been released to address this condition. Reprogram the PCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. - When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. - When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. - During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information Note *Please use Failure Code 93 for any warranty claims submitted using this bulletin. For vehicles repaired under warranty, use the table above. Page 2944 Page 4077 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 7254 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 16236 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9156 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 13317 Pressure Regulating Solenoid: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control (PC) Solenoid Valve, Wiring Harness Side Page 1819 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 15780 Alternator: Locations Left Side of Engine (4.3L) 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Top of Engine Diesel Page 7762 Body Control Module (BCM) X4 Page 2021 Vehicle Zoning Strategy Truck Zoning Page 2800 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. HVAC - Automatic Control Assembly: Diagrams HVAC - Automatic HVAC Connector End Views HVAC Control Module X1 HVAC Control Module X2 Page 24246 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 5141 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 2806 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 11604 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 8232 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Below the I/P Page 24248 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 4830 6. Inspect for evidence of improper arcing. * Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. * Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. * Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). * Inspect for a broken or worn side electrode (3). * Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. * Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. * Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. * Inspect for excessive fouling. 7. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection 1. Normal operation-Brown to grayish tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: * Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion * Reduced ignition system voltage output - Weak ignition coils - Worn ignition wires - Incorrect spark plug gap * Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not affect spark intensity unless they form into a glazing over the electrode. Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 3983 Page 22287 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Page 14264 Axle Shaft: Service and Repair Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) Rear Axle Shaft Replacement (8.6, 9.5/9.5LD Inch Axles) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper. 4. Remove the rear cover and the gasket. 5. Remove the pinion shaft locking bolt. 6. On axles without a locking differential, remove the pinion shaft. Page 24501 Note Remove the two relays (1) next to the fuse to gain access to the fuse. 4. Remove the 60 amp heated windshield washer fuse (2) using needle-nose pliers. 5. Discard the 60 amp heated windshield washer fuse. 6. Install the two relays (1) removed in Step 4. 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to Step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure that the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the heated windshield washer switch does NOT flash. 10. Secure the UBEC cover on the UBEC. 11. Close the hood. 12. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Note Involved vehicles that are currently in dealer/retailer new car inventory are to receive a corrected Monroney Label (MSRP window sticker). It is the responsibility of the Service Manager to ensure this label replacement occurs as soon as possible. 13. After this procedure has been performed, issue a check to the customer of record (see the Q&A; section in this buleltin for additional details). Involved vehicles that are currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Buick Lucerne, Cadillac DTS and CTS 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS The underhood bussed electrical center is located in the vehicle's front left-hand side of the engine compartment between the engine coolant recovery bottle and rearward of the radiator support housing. The "Heated Windshield Washer" fuse is in location "JC1", which is positioned in the rear center quadrant of the UBEC. 2008-2009 Buick Lucerne and Cadillac DTS The underhood bussed electrical center is located in the vehicle's front left-hand side of engine compartment between the engine coolant recovery bottle and rearward of the radiator support housing. The "Heated Windshield Washer" fuse is in location "F28", which is positioned in the rear inside quadrant of the UBEC. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Page 14760 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 5950 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 6776 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 16921 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 16280 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Page 8431 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Electrical - No Start/No Crank/Int Electrical Operations Wiring Harness: Customer Interest Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 16084 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 18758 Air Bag Deactivation Switch: Service and Repair Inflatable Restraint Instrument Panel Module Disable Switch Replacement Recall - Heated Windshield Washer Module Short Circuit Technical Service Bulletin # 08048C Date: 090429 Recall - Heated Windshield Washer Module Short Circuit SAFETY Bulletin No.: 08048C Date: April 28, 2009 Subject: 08048C - Heated Windshield Washer Module Short Circuit - Add Wire Harness Models: 2006-2008 Buick Lucerne 2008 Buick Enclave 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Acadia, Sierra, Yukon, Yukon XL 2006-2008 HUMMER H2 2007-2008 Saturn OUTLOOK Equipped with Heated Washer Fluid System .............................................................................................................................................................. .................................................................................. Supercede: The service procedure in this bulletin has been revised to include verification that the fluid system dispenses heated fluid. Please discard all copies of bulletin 08048B, issued October 2008. .............................................................................................................................................................. .................................................................................. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2006-2008 model year Buick Lucerne; Cadillac DTS; HUMMER H2 vehicles; 2007-2008 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK vehicles; and 2008 model year Buick Enclave vehicles equipped with a heated washer fluid system. A short circuit on the printed circuit board for the washer fluid heater may overheat the control-circuit ground wire. This may cause other electrical malfunctions, create an odor, or cause smoke. In rare cases, it may cause a fire. Correction Dealers/retailers are to install a wire harness with an in-line fuse. Vehicles Involved Involved are certain 2006-2008 model year Buick Lucerne; Cadillac DTS; HUMMER H2 vehicle; 2007-2008 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK vehicles; and 2008 model year Buick Enclave vehicles equipped with a heated washer fluid system and built within these VIN breakpoints: Locations Manifold Pressure/Vacuum Sensor: Locations Engine Controls Component Views Rear of the Engine 1 - Central Sequential Fuel Injection (SFI) Module 2 - Manifold Absolute Pressure (MAP) Sensor 3 G106 4 - Engine Oil Pressure (EOP) Sensor 5 - Ignition Control Module (ICM) 6 - G107 Page 1857 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6867 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Endgate Torque Rod Replacement Tailgate Hinge: Service and Repair Endgate Torque Rod Replacement Endgate Torque Rod Replacement Page 18617 Cabin Temperature Sensor / Switch: Diagrams HVAC Connector End Views Inside Air Temperature Sensor - Front 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Input Speed Sensor (ISS) Harness Page 23561 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 285 Memory Seat Module X3 (AN3) Page 15816 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Page 3359 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 7136 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 6427 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Tank Pressure Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 782 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Electrical - Battery Goes Dead Overnight Body Control Module: Customer Interest Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 11880 Page 16961 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 9265 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 2663 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13830 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 14179 11. Install the propeller shaft yoke retaining clamps and the bolts. Tighten the bolts to 25 N.m (18 lb ft). 12. Inspect and add axle lubricant to the axle housing, if necessary. 13. Lower the vehicle. Page 15464 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the left park brake cable (1) from the intermediate cable equalizer bar (2). 5. Release the left park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Remove the park brake cable clip bolt. Page 5003 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 17711 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Inlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Install drain pans under the vehicle as needed. Notice: Refer to Power Steering Hose Disconnected Notice. Important: Note the routing of the power steering gear inlet hose before removal. It MUST be routed correctly upon installation. 2. Remove the power steering gear inlet hose (2) from the power brake booster (1). 3. Remove the power steering gear inlet hose (2) from the power steering gear. 4. Remove the power steering gear inlet hose (2) from the vehicle. Installation Procedure Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. Page 20250 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 10217 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 9643 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 23793 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 12075 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 16213 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2729 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Drivetrain and Front Suspension Frame Front Crossmember Replacement (2WD 2500 HD, 3500) Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (2WD 2500 HD, 3500) Drivetrain and Front Suspension Frame Front Crossmember Replacement (2WD 2500 HD, 3500) Page 14833 Page 13844 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Brakes - Aftermarket Trailer Brake Controllers Trailer Connector: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 2229 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 17151 Junction Block - Left I/P X12 Page 13691 15. Remove the retainer securing the cable to the steering column. 16. Remove the cable end from the steering column ball stud. 17. Depress the tangs and remove the cable from the steering column bracket. Page 3148 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 21773 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Page 5859 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9618 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 4107 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 10157 Disclaimer Page 4942 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 14166 12. Install the pinion yoke. Align the marks made during removal. 13. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 14. Install the washer and a new pinion nut. 15. Install the J 8614-01 onto the pinion yoke as shown. Notice: Refer to Fastener Notice. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 16. Tighten the pinion nut while holding the J 8614-01. Tighten the pinion nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 17. Measure the rotating torque of the pinion using an inch-pound torque wrench. The rotating torque of the pinion should be between 1.0-2.3 N.m (10-20 lb in) for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings. 18. If the rotating torque measurement is below 1.0 N.m (10 lb in) for used bearings, or 1.7 N.m (15 lb in) for new bearings, continue to tighten the pinion nut. Tighten the pinion nut, in small increments, as needed, until the torque required in order to rotate the pinion is between 1.0-2.3 N.m (10-20 lb in) for used bearings, or 1.7-3.4 N.m (15-30 lb in) for new bearings. Page 12109 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 1086 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14550 Transmission Control Module (TCM), Engine Side A/T - Fluid Leak From Bell Housing Area Seals and Gaskets: All Technical Service Bulletins A/T - Fluid Leak From Bell Housing Area TECHNICAL Bulletin No.: 08-07-30-023 Date: May 08, 2008 Subject: 4L60-E/4L65-E/4L70‐E Automatic Transmission Fluid Leak from Oil Pump or Bell Housing Area (Replace Torque Converter Hub-to-Oil Pump Seal Assembly) Models: 2007-2008 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe, TrailBlazer 2007-2008 GMC Envoy, Savana, Sierra, Yukon, Yukon XL 2007-2008 HUMMER H2 2007-2008 Saab 9-7X with 4L60-E, 4L65-E or 4L70‐E Automatic Transmission (RPOs M30, M32 or M70) and 4.8L, 5.3L or 6.0L V8 Engine Attention: This bulletin applies to vehicles built prior to December 2007. Condition Some customers may comment on an automatic transmission fluid leak. Upon further investigation, the technician may find fluid leaking from the oil pump or bell housing area. Cause Investigation of 2007 transmissions has shown wear of the torque converter hub-to-pump seal (243, illustrated in the Oil Pump Disassembled View in SI). Correction Verify that the leak is coming from the oil pump or bell housing area by the use of oil dye in the transmission. Refer to Fluid Leak Diagnosis in SI. Clean the transmission suspected area of all residual oil and drive the vehicle to see if the dye begins to appear. If the leak is coming from the bell housing replace the torque converter seal. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 11917 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 19869 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Page 21671 Page 14717 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Specifications Idle Speed: Specifications Information not supplied by the manufacturer Page 2108 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 2734 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 1562 Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Page 726 Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 17808 For vehicles repaired under warranty, use the table. Disclaimer Page 197 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Audio System - Static/Ignition Noise on AM Band Ignition Cable: All Technical Service Bulletins Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Page 2353 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 20391 Trailer Hitch: Service and Repair Trailer Hitch Replacement (Heavy Duty) Trailer Hitch Replacement (Heavy Duty) Removal Procedure 1. Remove the hitch platform bolts (5) from the bumper weld nuts (4). 2. Remove the nuts (7) and bolts (1) securing the hitch platform to the frame rails. 3. Remove the hitch platform bolts (6) from the frame weld nuts (2). 4. Remove the hitch platform from the vehicle. Installation Procedure 1. Position the hitch platform to the vehicle. Page 5028 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 18800 Disclaimer Page 6829 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 9429 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 16465 X211 Instrument Panel Harness (Y91) Or I/P Extension Harness (-Y91) To Console Harness (Y91/UQA/D07) (Pin C7 To D8) X212 Inline Harness Connector End Views X212 Instrument Panel Harness to Instrument Panel Extension Harness (-Y91) Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required j 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the oil pressure sensor. Do not allow debris to enter the engine. 1. Disconnect the fuel pump/oil pressure sensor electrical connector (3). 2. Using J 41712, remove the fuel pump/oil pressure sensor. Page 8831 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Page 18775 1 - Window Switch - Right Rear (ABV) 2 - Window Motor - Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 4 - Speaker - Right Rear Door Left Rear Door (Crew Cab) Page 512 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 6171 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 16264 Fuse Block - I/P X4 Page 9872 View of the connector when released from the component. View of another type of Micro 64 connector. Page 20870 For vehicles repaired under warranty, use the table above. Disclaimer Page 23875 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 6500 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 2362 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 18541 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 2291 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 15354 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered, non-lubricated compressed air. Assembly Procedure Important: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure that the square-cut piston seal is not twisted. Page 10400 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 13357 Control Module: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Service and Repair Windshield Washer Hose: Service and Repair Windshield Washer Hose Replacement Page 17197 For vehicles repaired under warranty, use the table. Disclaimer Page 12585 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 23052 Page 2300 4. Reposition the knock sensor sleeve (2) down, away from the knock sensor. 5. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. 6. Remove the knock sensor bolt and sensor. Installation Procedure Page 2479 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 15167 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Page 11528 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 17547 For vehicles repaired under warranty, use the table. Disclaimer Page 9090 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 1788 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 12139 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 6461 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 21702 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 13497 Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Notice: Refer to Fastener Notice. 3. Install the speed sensor bolt (1). Tighten bolt to 12 N.m (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Power and Grounding Component Views Fuse Block: Locations Power and Grounding Component Views Power and Grounding Component Views Left Side of the Engine Compartment 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (- MYC) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Engine Harness Jumper to Engine POA Harness Diesel Page 16949 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 3406 Transmission Speed Sensor: Locations Power Take-Off Power Take-Off (PTO) Component Views Front Frame Rail 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor 4 - Automatic Transmission Input Shaft Speed (AT ISS) Sensor 5 - Automatic Transmission 6 - Vehicle Speed Sensor (VSS) 7 - X124 8 - Power Take Off (PTO) Module 9 - X175 Page 13963 Warranty Information For repairs performed under warranty, use the applicable published labor code. Disclaimer Diagram Information and Instructions Torque Converter Clutch Solenoid: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 8468 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 23008 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 22214 Page 15962 Branching Point: Diagrams JX300 - JX399 Splice Pack Connector End Views JX339 Page 3389 Transmission Position Switch/Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 10561 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 5303 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 15215 Front Brake Caliper Bracket Replacement (JH6, JH7) Front Brake Caliper Bracket Replacement (JH6, JH7) Page 15846 Page 16053 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 6207 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 5177 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 10094 19. If equipped with 4WD perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service. 20. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. 21. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 22. Remove the fuel line bracket bolt (1). 23. Remove the fuel/EVAP line clip nut (2). 24. Remove the fuel/EVAP line clips from the frame and crossmember. 25. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure 1. If equipped with 4WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Notice: Refer to Fastener Notice. Page 12263 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 2904 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 12996 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 20716 Front Door Panel: By Symptom Technical Service Bulletin # 07-08-110-010A Date: 080414 Interior - Front Door Panel Rattles Loose TECHNICAL Bulletin No.: 07-08-110-010A Date: April 14, 2008 Subject: EI07321 - Inner Door Panel Rattle Noise/Loose (Inspect/Replace Clips) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Supercede: This bulletin is being revised to end the need for technician feedback and to provide corrective action. Please discard Corporate Bulletin Number 07-08-110-010 (Section 08 - Body and Accessories). Condition Some customers may comment on any of the following conditions: ^ a rattling noise coming from inside the door or the door panel ^ a poor fit of the inner door panel ^ a loose door panel Cause Engineering has determined that some of the door panel clips may have been damaged during assembly. Correction DO NOT REPLACE THE DOOR TRIM PANEL. Remove the interior door panel and inspect the clips for damage. Replace the clips if necessary and reinstall the door panel. If the clips are not missing or damaged, it is possible to correct the customers concern by reinstalling the door panel, ensuring the clips are fully seated. In the event that the customers concern is NOT related to the clips or corrected by reinstalling the door panel submit a Field Product Report (refer to bulletin # 02-00-89-002F). This information will provide engineering with the cause and correction of the customers complaint. Parts Information Important: There are a total of seven (7) white retainers and four (4) black retainers used per door trim panel. The retainers are shipped one per package. The technician will need to determine how many of each retainer is necessary to complete the repair. Warranty Information Page 9196 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16163 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 22963 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 22409 Page 8335 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 2422 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 16473 X277 Inline Harness Connector End Views X277 Inflatable Restraint Steering Wheel Module Coil to Heated Steering Wheel Harness (KA9) X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Harness (Gas) Page 12225 View of the connector when released from the component. View of another type of Micro 64 connector. Page 16663 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 5464 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Lighting - Brake Lamps Turn Off After Stop/Pedal Applied Brake Light Switch: Customer Interest Lighting - Brake Lamps Turn Off After Stop/Pedal Applied TECHNICAL Bulletin No.: 08-08-42-003A Date: August 14, 2009 Subject: Stop Lamps Intermittently Turn Off After Coming to a Complete Stop While Still Having Pressure on Brake Pedal (Replace Stop Lamp Switch) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to provide a new part number. Please discard Corporate Bulletin Number 08-08-42-003 (Section 08 - Body & Accessories). Condition Some customers may comment on the stop lamps turning off prior to the brake pedal reaching the fully released position. Some customers may also comment on the stop lamps turning off while having light pressure on the brake pedal. Some customers with Integrated Trailer Brake Control (ITBC) may comment that the electronic trailer brakes disengage after the vehicle has come to a complete stop. This disengaging of the trailer brakes coincides with the stop lamps turning off. Cause This condition may be caused by not enough pressure being applied to the stop lamp switch to keep the brake lights on. Correction Technicians are to replace the stop lamp switch. The new stop lamp switch has a reduced internal spring apply force, which will allow the lamps to stay on with less applied brake force. 1. Refer to SI for Stop Lamp Switch replacement procedures. 2. Use the new Stop Lamp Switch, P/N 25981009. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 13032 Page 13841 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 5931 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 22219 Rear Seat Back Cushion Frame Replacement (Crew Cab with A68) Rear Seat Back Cushion Frame Replacement (Crew Cab with A68) Page 1040 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 14280 3. Hold the inner race (1) at 90 degrees to the centerline of the cage (2). 4. Align the lands of the inner race (1) with the windows of the cage (2). 5. Insert the inner race (1) into the cage (2), by rotating the inner race (1) downward. 6. Insert the cage (4) and inner race into the outer race (1). Page 15830 3. Install the engine wiring harness lead (5) to the starter. Notice: Refer to Fastener Notice. 4. Install the engine wiring harness lead nut (2). Tighten the nut to 3.4 N.m (30 lb in). 5. Install the starter solenoid cable lead (2) to the starter. 6. Install the starter solenoid cable (1) nut. Tighten the nut to 9 N.m (80 lb in). Page 23907 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 4881 Vehicle Zoning Strategy Truck Zoning Page 12334 Fluid Pressure Sensor/Switch: Specifications Allison - Automatic Transmission Pressure Switch Manifold (PSM) Logic Pressure Switch Manifold (PSM) Logic Page 11318 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Electrical - Various Rear Door Electrical Malfunctions Wiring Harness: Customer Interest Electrical - Various Rear Door Electrical Malfunctions TECHNICAL Bulletin No.: 06-08-44-009A Date: August 04, 2008 Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007-2009 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-45-009 (Section 08 - Body and Accessories). Condition Some customers may comment on one or all of the following conditions: ^ Rear door locks inoperative ^ Rear windows inoperative ^ Door courtesy lamps inoperative or stay on at times ^ Rear speakers inoperative ^ Any fuse (related to the rear doors) that is blown/shorted ^ SIR codes related to the pretensioner ^ Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction Important: This repair operation is intended to be done on both B-pillars. 1. Remove the lower B-pillar cover. 2. Disconnect the Supplemental Inflatable Restraint (SIR) connector. 3. Inspect the wiring harness in the B-pillar around the seat belt retractor. 4. Make any necessary wiring harness repairs. 5. Wrap the "entire" harness with electrical tape. 6. Install conduit tubing around the harness. Page 339 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 15859 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 18328 Disclaimer Page 3474 Wheel Alignment Specifications (Part 2) Page 5386 Radiator Cooling Fan Motor Relay: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 4561 Disclaimer Page 2237 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Procedures Steering Angle Sensor: Procedures Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 15825 1 - Fuel Injector 7 2 - Fuel Injector 5 3 - Fuel Injector 3 4 - Exhaust Gas Recirculation (EGR) Valve 5 - Fuel Injector 1 6 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 7 - Intake Air Valve 8 - Crankshaft Position (CKP) Sensor 9 - Glow Plug 1 10 - G103 11 - G105 12 - Block Heater 13 - Glow Plug 3 14 - Glow Plug 5 15 - Water In Fuel Sensor 16 - Starter 17 - Glow Plug 7 Locations Knock Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 21599 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Body - Soft Tonneau Cover Appears Loose/Won't Latch Truck Bed Cover Latch: Customer Interest Body - Soft Tonneau Cover Appears Loose/Won't Latch TECHNICAL Bulletin No.: 09-08-66-004A Date: January 04, 2011 Subject: Roll Up Soft Tonneau Cover Appears Loose or Latch Not Functioning Properly (Adjust Upper Side Rail Clamps and/or Rails and/or Replace Rear Latch) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Attention: This bulletin only applies to vehicles with tonneau part numbers 19213900, 19213901, 19213902, 19213903, 19213904 and 19213905. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-08-66-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the roll up soft tonneau cover is too loose, or that the tonneau cover latch is disengaging and not staying closed. Two improvements have been implemented since the original release of the tonneau cover. Be sure that the tonneau cover meets the criteria of the items below. Cause #1 The condition may be caused by improper installation of one or more of the upper side rail clamps. Using the outer groove (1) when a molded bed rail protector IS NOT installed may cause a gap (2) between the pad and pickup box. This may also prevent proper latch retention. Correction #1 Note Page 17165 Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Top View - Gas Fuse Block - Underhood, Bottom View Page 8480 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 16248 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 22626 Seat Recline Position Sensor - Driver (AN3) Page 21893 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 24241 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 12953 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 19555 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Page 3286 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Page 9602 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 7792 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 6725 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 24709 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 5818 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 8621 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 11249 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 10604 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 9462 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Interior - Front/Rear Drink Holder Won't Retain Drinks Drink Holders: All Technical Service Bulletins Interior - Front/Rear Drink Holder Won't Retain Drinks Bulletin No.: 07-08-49-002 Date: January 24, 2007 TECHNICAL Subject: Front Floor Rear Console Cupholder Does Not Properly Retain Drink Containers (Install Updated Rear Console Cupholder Liner) Models: 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Denali, Sierra, Yukon Models with Center Console (RPO D07) Condition Some customers may comment that the front floor rear console cupholder can not retain drink containers while driving. Cause The current rear console cupholder mats do not have any retainers to properly hold the container while turning or accelerating, causing the container to tip over or fall out. Correction Replace the existing mats with the updated one piece cupholder liner using the procedure below: Open the front floor rear console cupholder assembly. Remove the existing two rear cupholder mats. Refer to the graphic above. Discard the old cupholder mats. Obtain an updated cupholder liner. The liner will have four outer tabs and inner retainers. Page 7768 Auxiliary Body Control Module (XBCM) X2 (Export) Page 5428 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 2150 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 17071 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 9711 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 10244 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7705 Disclaimer Page 24388 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Page 18910 Air Bag Control Module: Diagrams SIR Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) (Extended/Crew Cab +10 Series +ASF) Page 13865 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 2305 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (3) up and over the knock sensor. 4. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 5. Lower the vehicle. Page 878 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 16274 Junction Block - Left I/P X5 (SPO Alarm) Junction Block - Left I/P X7 (JF4) Page 21089 Hood Shock / Support: Service and Repair Hood Strut Replacement Hood Strut Replacement Page 6362 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 6273 Vehicle Zoning Strategy Truck Zoning Page 18553 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 9917 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 17330 X320 Inline Harness Connector End Views X320 Body Harness to Sliding Rear Window Jumper Harness (A48) X321 Page 18305 Compressor Clutch: Diagrams HVAC - Manual HVAC Connector End Views A/C Compressor Clutch (C67) Page 2686 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 18001 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 4036 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 14847 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 16375 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 17510 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 11130 Page 11607 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 9578 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 10564 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 21243 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 7520 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the appropriate spark plug wire boot(s) (2) from the spark plug. (left side shown, right similar). 1. Twist the spark plug boot 1/2 turn. 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose in order to remove the spark plug wire boot from the spark plug. 2. Loosen the spark plug 1 or 2 turns. (left side shown, right similar). 3. Brush or air blast away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than 1 plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Page 2249 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18440 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement Sealing Washer Replacement Removal Procedure 1. Remove the seal washer from the A/C refrigerant component. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: DO NOT reuse sealing washer. 4. Discard the sealing washer. Installation Procedure Important: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. Important: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Page 21396 Front Floor Console Compartment Replacement (Except Cadillac) Front Floor Console Compartment Replacement (Except Cadillac) Service and Repair Ignition Switch Lock Cylinder: Service and Repair Key and Lock Cylinder Coding Use Instruction Sheet Supplied For the lock cylinder coding procedure, refer to the instruction sheet supplied in the lock cylinder kit. For key cutting information, refer to the instructions provided from the manufacturer of the key cutting equipment used. Page 15042 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 34 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 19811 Diagnostic Tips Review Table Page 5371 Page 18574 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2266 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 9304 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 11272 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 10695 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Clip the line assembly to the frame. 3. Tighten the BPMV bolts. 4. Install the fuel/EVAP line bracket locator tab to the frame. 5. Install the fuel/EVAP line clips to the frame and crossmember. 6. Clip the inline electrical connector to the bracket. Notice: Refer to Fastener Notice. 7. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 N.m (80 lb in). 8. Install the fuel/EVAP line clip nut (2). Tighten the nut to 20 N.m (15 lb ft). 9. Remove the caps from the fuel and EVAP lines. 10. Connect the fuel tank EVAP line quick connect fitting to the chassis line. 11. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Page 9317 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 9222 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 23592 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 12618 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 8329 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 4076 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 15891 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 4973 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 2384 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 9434 Page 17403 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Page 16934 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 22205 Front Center Seat Back Cushion Latch Replacement (AE7) Front Center Seat Back Cushion Latch Replacement (AE7) Page 21311 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Page 5858 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 17242 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 8203 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 18907 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 12823 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16239 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 22126 11 - Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) 12 - Seat Adjuster Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Page 24700 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 2893 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 2387 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Page 23023 Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Steering Wheel Control Switch Assembly Replacement * Programming and Relearning for BCM setup, and programming. See: Testing and Inspection/Programming and Relearning Cruise Control Switch Indicator Inoperative Cruise Control Switch Indicator Inoperative Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provides an overview of each diagnostic category. Circuit/System Description The body control module (BCM) monitors the cruise control indicator switch. When the cruise on/off switch is pressed ON, the cruise control switch is closed and the signal circuit is low. When the cruise on/off switch is pressed OFF, the cruise control switch is open and the signal circuit is high. Circuit/System Testing 1. Ignition OFF, disconnect the cruise control switch assembly. 2. Connect a fused jumper between the voltage signal circuit and the low reference circuit. 3. Ignition ON, observe the Cruise On/Off Switch parameter. ‹› If the Cruise On/Off Switch parameter displays ON, replace the cruise control switch assembly. ‹› If the Cruise On/Off Switch parameter displays Off, test the voltage signal circuit and the low reference circuit for an open, or for a high resistance. 4. If all circuits test normal, replace the BCM. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Steering Wheel Control Switch Assembly Replacement * Programming and Relearning for setup, and programming. See: Testing and Inspection/Programming and Relearning Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 13417 2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the bore until it is seated at the bottom of the bore. 4. Install the PNP switch. 5. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Check. Propeller Shaft Front Slip Yoke Oil Seal Replacement Propeller Shaft Front Slip Yoke Oil Seal Replacement Tools Required * J 21426 Extension Housing Seal Installer * J 36850 Transjel Lubricant Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. 4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. 5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal with J 36850. 2. Use the J 21426 with a soft faced mallet to install the seal. 3. Install the seal to the extension housing. 4. Install the propeller shaft. 5. Remove the drain pan and lower the vehicle. 6. Fill the transmission to the proper level with DEXRON(R) III transmission fluid. Refer to Transmission Fluid Check. A/C - HVAC Control Module Lockup During Reprogramming Control Module HVAC: All Technical Service Bulletins A/C - HVAC Control Module Lockup During Reprogramming Bulletin No.: 06-01-39-014 Date: December 06, 2006 INFORMATION Subject: Information On HVAC Control Module Lockup During Reprogramming Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) The purpose of this bulletin is to alert technicians to a condition they may encounter while trying to reprogram a Heating, Ventilation and Air Conditioning (HVAC) control module. If the HVAC control module reprogramming event is interrupted, the control module may go into a "lock up" mode. This will cause the HVAC control module to disable communications and a second try at reprogramming will fail. The interruption may be caused by a software anomaly inside the HVAC control module. If the HVAC reprogramming event was interrupted and a subsequent reprogramming attempt fails, perform a battery reset. This can be accomplished by either removing and reinstalling the HVAC BATT fuse, located in the underhood fuse block, or by disconnecting and reconnecting the HVAC control module connector C2. Connector C2 is grey in color with 16 cavities. Once the battery reset has been performed, the HVAC control module will resume communications and will then be able to be reprogrammed. The Warranty Parts Center (WPC) has received HVAC control modules that have been returned and described as non-functional but were tested with no problems found. If the module has been replaced due to a failed second attempt at reprogramming caused by the lock up, the module will be returned and charged back to the dealer. Technicians must also remember that after a new HVAC control module has been installed into a vehicle, it must be programmed, otherwise it will not be functional. Disclaimer Page 21924 Memory Seat Module X7 (AN3) Page 4651 13. Remove the manual transmission bolts, if equipped. 14. Remove the automatic transmission bolts, if equipped. Page 11868 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Reluctor Ring Replacement Crankshaft Position Sensor Reluctor Ring Replacement Tools Required j 5590 Rear Pinion Bearing Race Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position (CKP) sensor reluctor ring. Installation Procedure Page 22731 Tailgate Latch: Service and Repair Pickup Box Endgate Striker Replacement (Pickup Box) Pickup Box Endgate Striker Replacement (Pickup Box) Page 7521 1. Ensure that the spark plug washer is positioned correctly. 2. Inspect the spark plug gap. Adjust the gap as needed. 3. Install the spark plug into the cylinder head by hand. (left side shown, right similar). Notice: Refer to Fastener Notice. 4. Tighten the spark plug. Tighten the plug to 15 N.m (11 lb ft). 5. If reinstalling the old spark plug wires, apply dielectric grease GM PN 12345579 (Canadian PN 10953481), or equivalent to the inside the spark plug wire boots. 6. Install the appropriate spark plug wire boot(s) (2) to the spark plug. (left side shown, right similar). Page 2195 Vehicle Zoning Strategy Truck Zoning Page 17365 X220 Inline Harness Connector End Views X220 Brake Clutch Harness to Chassis Harness (JL1) X224 Inline Harness Connector End Views X224 Brake Clutch Harness to Beacon Harness (5Y0/5X7) Page 11713 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 16469 X225 Inline Harness Connector End Views X225 Brake Clutch Harness to Battery Positive Harness (9L4) Page 10922 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 7517 Spark Plug: Application and ID Spark Plug Type................................................................................................................................... ................GM P/N 126078234 AC Delco P/N 41-993 Page 20881 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Interior - Lint Accumulation On Ebony Colored Seats Arm Rest: All Technical Service Bulletins Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 15147 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement (JH6, JH7) Brake Pressure Modulator Valve Replacement (JH6, JH7) Page 13887 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 10589 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 23867 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 14324 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Page 1686 Ambient Light Sensor: Diagrams HVAC - Automatic HVAC Connector End Views Ambient Light/Sunload Sensor Assembly Locations Sunroof / Moonroof Switch: Locations Sunroof Component Views Front Headliner Components 1 - Inside Air Temperature Sensor - Front (CJ2) 2 - Cellular Microphone (UE1/U3U/UVB) 3 Courtesy/Reading Lamps - Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade - Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly 8 - Inside Rearview Mirror (ISRVM) 9 - Courtesy/Reading Lamps - Front 10 - Windshield 11 - Sunshade - Left (DH6) Page 1848 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 21475 Scuff Plate: Service and Repair Rear Side Door Sill Plate Replacement (Crew Cab) Rear Side Door Sill Plate Replacement (Crew Cab) Page 20372 Trailer Brake Controller Module (TBCM) Page 301 Memory Seat Module X3 (AN3) Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 21029 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Plate Replacement (Extended Cab) Rear Side Door Sill Plate Replacement (Crew Cab) . Page 2263 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 8781 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 5398 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 19311 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Locations Air Flow Meter/Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 12902 Page 12766 4. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Tighten the bolt to 11 N.m (97 lb in). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), Page 9391 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 10101 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis line. 12. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. 13. Disconnect the chassis EVAP line quick connect fitting from the EVAP canister. 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (1). 16. Remove the fuel/EVAP line clip nut (2). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Allison - Automatic Transmission Pressure Regulating Solenoid: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Mod Main Pressure Control Solenoid Pressure Control Solenoid 1 (PCS1) Pressure Control Solenoid 1 (PCS1) Page 21519 Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/A48) Page 7519 6. Inspect for evidence of improper arcing. * Measure the gap between the center electrode (4) and the side electrode (3) terminals. An excessively wide electrode gap can prevent correct spark plug operation. * Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. * Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). * Inspect for a broken or worn side electrode (3). * Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. * Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. * Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. * Inspect for excessive fouling. 7. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Visual Inspection 1. Normal operation-Brown to grayish tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. 2. Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: * Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element - Incorrect combustion * Reduced ignition system voltage output - Weak ignition coils - Worn ignition wires - Incorrect spark plug gap * Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. 3. Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not affect spark intensity unless they form into a glazing over the electrode. Page 619 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 13806 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 12831 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 18459 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 14634 Transmission Speed Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Input and Output Speed Sensor Replacement Page 21544 Door Module: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 8099 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 11569 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 13200 Page 3011 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 23821 10. Twist the end of circuit 3040 together with circuit 240. Connect the circuits from the side of the circuit that does not have a terminal. Important: Apply heat to sleeve using a hot air gun or Ultratorch. Apply heat to the center of the sleeve and continue heating for a minimum of 30 seconds. Once the glue starts to melt, slowly rotate the sleeve while applying heat evenly until hot glue is visible outside the sleeve. 11. Using a BLUE colored crimp and seal splice sleeve PN 12089190, crimp the 240/3040 end to the 3040 end. Refer to Splicing Copper Wire Using Splice sleeves in SI, if required. 12. Re-apply tape (1) to the harness. 13. Plug the 40-way connector X1 back into the backside of the LBEC. 14. Verify that there is power to the beacon switch by activating the switch. If the beacon switch light indicator illuminates when the switch is in the ON position and turns off when the switch is in the OFF position, the repair has been performed correctly. 15. Install the instrument panel (I/P) knee bolster. Refer to Knee Bolster Replacement in SI. 16. Install the park brake release handle. Refer to Park Brake Release Handle Assembly Replacement in SI. Claim Information For vehicles repaired under this service update, use the table. Page 994 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 18875 Warranty Information (Saab U.S. Models) Disclaimer Page 1979 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 5231 For vehicles repaired under warranty, use the table. Disclaimer Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 3756 Disclaimer Page 21746 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Page 3651 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 22929 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 8418 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 10747 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 12799 Page 12537 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2735 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Service and Repair Power Mirror Motor: Service and Repair Outside Rearview Mirror Motor Replacement Page 9221 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 933 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 16116 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 235 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 23729 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8199 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Page 11710 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 2283 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 8111 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 6910 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 17765 3. Tighten the steering linkage shock absorber nuts (1, 3). Tighten the nuts to 40 N.m (30 lb ft). 4. Install the engine shield, if equipped. Page 24329 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 9388 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 6231 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 20521 Page 3071 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 17753 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Page 2733 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 10247 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 9331 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 3840 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 14784 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 9621 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 22940 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 8000 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 10544 Page 8549 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11284 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 21651 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 23015 Page 9498 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 3593 Disclaimer Page 6660 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 18496 Hose/Line HVAC: Service and Repair Suction Hose Replacement (With RPO Code LY2, LMF, L76 and L92) Suction Hose Replacement (LY2, LMF, L76 and L92) Tire/Wheel - Spare Tire Is Non-Matching To Other Tires Spare Tire: Technical Service Bulletins Tire/Wheel - Spare Tire Is Non-Matching To Other Tires INFORMATION Bulletin No.: 02-03-10-001E Date: November 01, 2010 Subject: Spare Tire is a Different Size than Other Tires Models: 2002-2011 Cadillac Escalade Models 1999-2007 Chevrolet Silverado (Classic) 2000-2011 Chevrolet Suburban, Tahoe 2002-2011 Chevrolet Avalanche 1999-2007 GMC Sierra (Classic) 2001 GMC Sierra C3 2001-2011 GMC Yukon Models 2002-2011 GMC Sierra Denali Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-03-10-001D (Section 03 - Suspension). This bulletin is being issued to supply additional information concerning the spare tire on the above vehicles. You or your customers may have noticed that the spare tire has a 16-inch diameter steel wheel or 17-inch diameter aluminum wheel while the road tires have a 17-inch, 18-inch, 20-inch or 22-inch diameter aluminum wheel. Although the spare tire has a different wheel diameter and may be a different brand, the rolling circumference is nearly identical to the road tires. The size difference will not cause a concern because the spare and the other tires will travel the same distance in one revolution. This combination of non-matching tires is used most often on full-size trucks. These vehicles use a road tire and wheel combination that may be too large to conveniently fit the storage compartment space of the vehicle. The customer may not be able to easily remove the spare tire/wheel from the storage area because of its size and/or weight. A steel spare wheel, rather than an aluminum one, may be used since the spare is stowed under the vehicle where it is exposed to road and weather elements. A steel wheel is less likely to incur cosmetic damage while in the stowed position for long periods of time. Please provide this information to your customers. Also, remind your customers of the importance of following the tire maintenance schedule as listed in their Owner Manual. Additional tire care information can be found by visiting www.gmtiresafety.com or contacting GM toll-free. Disclaimer Lighting - Turn Signals Have Increased Flash Rate Body Control Module: All Technical Service Bulletins Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4542 Disclaimer Page 12064 Page 17378 X306 Inline Harness Connector End Views X306 Headliner Harness to Right A-Pillar Harness (U42) Page 6250 Page 8931 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 1558 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Page 4223 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 16443 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Page 7356 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 10410 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 23541 Clearance Lamp - Right Rear (RO5) Clearance Lamps (U01) Page 5519 13. For vehicles equipped with 4WD perform the following steps, connect the engine wiring harness electrical connector (7) to the left front HO2S electrical connector (8). 14. Install the left front CPA retainer. 15. Connect the engine wiring harness electrical connector (1) to the left rear HO2S electrical connector (2). 16. Install the left rear HO2S electrical connector clip to the frame. 17. Install the CPA retainer. Page 13000 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 15101 Transmission Speed Sensor: Locations Power Take-Off Power Take-Off (PTO) Component Views Front Frame Rail 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor 4 - Automatic Transmission Input Shaft Speed (AT ISS) Sensor 5 - Automatic Transmission 6 - Vehicle Speed Sensor (VSS) 7 - X124 8 - Power Take Off (PTO) Module 9 - X175 Diagrams Fuel Tank Unit: Diagrams Displays and Gages Connector End Views Fuel Pump and Sender Assembly - Front (Gas) Fuel Pump and Sender Assembly - Rear (Gas +LY6) Page 9123 Air Flow Meter/Sensor: Connector Views Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 15315 Page 11192 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 12805 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 21152 7. Install the fasteners to the reveal molding, starting from the top. Refer to Windshield Side Reveal Molding Replacement in SI. 8. Lifting the top edge of the reveal molding, grab the tail of the release lining and pull downward removing the lining. 9. Press or roll the reveal molding against the windshield ensuring adhesion of the tape to the glass. 10. Repeat steps 6-9 on the opposite side. 11. Remove tape or clean the grease pencil marks from the windshield. 12. If positioned correctly, trimming of the double sided tape should not be necessary, however inspect the reveal moldings for any tape not covered and trim off any exposed tape. Important After taping the windshield reveal moldings, avoid washing the vehicle as well as excessive contact with the windshield reveal moldings for a minimum of 72 hours. Parts Information 3M(TM) products may be purchased through your local distributor. Information about 3M product retailers in your area may be obtained by calling 1-866-364-3577 (U.S. and Canada). Warranty Information Page 21590 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 16296 Fuse Block - Underhood X2 (Pin A1 To M5) Page 5099 Page 22553 Page 13812 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 22380 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 12569 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 15639 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement Page 8906 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 7911 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 9962 Vehicle Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor (VSS) Page 21625 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 315 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 3041 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 14917 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 18540 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 16359 GM Engineering is seeing an increase in HVAC control head and actuator warranty where the component is fully functional when received. The root cause of the failure is intermittent wiring connections at the right hand BEC. Specifically, poor terminal tension of the 5V reference or Low Reference terminals in the X4 connector. Refer to the table. After the fault is removed. the actuators recover once commanded. Correction DO NOT REPLACE THE CONTROL HEAD. Use the following information to diagnose this condition: Page 9380 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Interior - Cleaning Interior Surfaces of Vehicle Carpet: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Page 11715 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 6796 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 8076 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 20031 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 15563 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 451 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 10568 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 16704 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 23648 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 9174 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 3975 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 14722 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 916 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 10592 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3024 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 16172 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 6791 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 12027 Pressure Regulating Solenoid: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control (PC) Solenoid Valve, Wiring Harness Side Page 1502 Page 3337 Tighten the bolt to 11 N.m (97 lb in). 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. Tighten the bolts to 11 N.m (97 lb in). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Lighting - Dome/Reading Lamps Inoperative Map Lamp: Customer Interest Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 9302 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 13849 Page 9251 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor from the cylinder head. Installation Procedure Notice: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, Page 272 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 7333 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 2571 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Notice: Refer to Fastener Notice. 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 N.m (92 lb in). 5. Install the control valve assembly. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure. Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Page 24120 Turn Signal/Malfunction Switch X3 Page 17504 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Locations Entertainment System Control Module: Locations Entertainment/Communication Component Views Headliner and Overhead Console (U42/5Y0) 1 - Roof Beacon Switch (5Y0) 2 - Video Display (U42) 3 - Infrared Module (U42) 4 - Emergency Vehicle Wiring Blunt Cuts (5Y0) 5 - Emergency Vehicle Roof Lamp Relay (5Y0) Page 17323 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Page 5310 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 7061 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 5166 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 7877 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 10864 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 4824 5. Install the appropriate spark plug wire boot(s) (1, 2) to the ignition coil. 6. Inspect the spark plug wires for proper routing (1, 2, 3, 4, 5, 6) and installation. 1. Push sideways on each boot in order to inspect the seating. 2. Reinstall any loose boot. 3. Any time the spark plug wire or boot are installed on the spark plug, new dielectric grease needs to be applied inside the boot. Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 5608 Tighten the right exhaust manifold pipe bolts in the sequence indicated in illustration "B" above. Tighten: Tighten the bolts to 50 N.m (37 lb ft). Tighten the Y-pipe outlet to the exhaust muffler assembly. Tighten: Tighten to 45 N.m (33 lb ft). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 7907 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 17558 For vehicles repaired under warranty, use the table. Disclaimer Page 14054 9 - Retaining Clip 10 - Modulated Main Valve Body 11 - Bolt, M6 x 10 x 65 12 - Bolt, M6 x 10 x 50 13 - O-Rings 14 - Modulated Main Pressure (MAIN MOD) Solenoid 15 - 6 Speed Pipe Shift Valve Body Assembly Disassembled Views Shift Valve Body Assembly 1 - Shift Valve Body Assembly 2 - Retaining Clip 3 - Shift Solenoid 2 (SS2) Shift Plug 4 - SS2 Shift Spring 5 - SS2 Shift Valve 6 - Retaining Clip 7 - SS3 Shift Plug 8 - SS3 Shift Spring 9 - SS3 Shift Valve Page 11942 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9833 Page 24152 Vehicle Zoning Strategy Truck Zoning Page 12913 Tighten the bolt to 11 N.m (97 lb in). 6. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 9. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 3932 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 1013 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 11138 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 203 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 2382 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 12891 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 12607 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: All Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Page 12125 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 10112 4. Inspect for fuel leaks. Page 21877 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 7608 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 8081 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 16278 Junction Block - Left I/P X12 Page 2396 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 21592 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 9964 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Page 2924 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 5306 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 2251 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 11911 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 2526 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 21524 Page 13768 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 8165 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: Customer Interest Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 8970 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 20988 Page 3176 Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (2) up and over the knock sensor. Page 7034 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 10337 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 14206 1. Install the axle shaft bearing using the J 23690 (8.6 inch and 9.5 inch LD axles) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128 (8.6 inch and 9.5 inch LD axles) or the J 29713 (9.5 inch axle). 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. 6. Install the rear axle housing cover. 7. Install the tire and wheel assembly. 8. Fill the rear axle. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 9. Lower the vehicle. Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 7840 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 16295 Page 10917 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 4174 Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE MONITOR SYSTEM The Tire Pressure Monitor System (TPMS) uses radio and sensor technology to check tire pressure levels. If your vehicle has this feature, sensors are mounted on each tire and wheel assembly, except the spare tire. The TPMS sensors monitor the air pressure in your vehicle's tires and transmit tire pressure readings to a receiver located in the vehicle. The TPMS is designed to alert the driver, if a low tire pressure condition exists. If your vehicle has the Driver Information Center (DIC), the driver may also check tire pressure levels using the DIC. When a low tire pressure condition is detected, the TPMS will illuminate the low tire pressure warning symbol located on the instrument panel cluster. If your vehicle has the DIC feature, a message to check the pressure in a specific tire will also appear on the DIC display. The low tire pressure warning symbol on the instrument panel cluster and the "CHECK TIRE PRESSURE" warning message on the DIC display will appear at each ignition cycle until the tires are inflated to the correct inflation pressure. You may notice, during cooler weather conditions, that the tire pressure monitor light, located on the instrument panel cluster, and the "CHECK TIRE PRESSURE" message will appear when the vehicle is first started and then turn off as you start to drive the vehicle. This could be an early indicator that the tire pressures are getting low and need to be inflated to the proper pressure. Each tire, including the spare (if provided), should be checked monthly when cold and inflated to the inflation pressure recommended by the vehicle manufacturer on the vehicle placard or tire inflation pressure label. (If your vehicle has tires of a different size than the size indicated on the vehicle placard or tire inflation pressure label, you should determine the proper tire inflation pressure for those tires.) As an added safety feature, your vehicle has been equipped with a tire pressure monitoring system (TPMS) that illuminates a low tire pressure telltale when one or more of your tires is significantly under-inflated. Accordingly, when the low tire pressure telltale illuminates, you should stop and check your tires as soon as possible, and inflate them to the proper pressure. Driving on a significantly under-inflated tire causes the tire to overheat and can lead to tire failure. Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle's handling and stopping ability. Please note that the TPMS is not a substitute for proper tire maintenance, and it is the driver's responsibility to maintain correct tire pressure, even if under-inflation has not reached the level to trigger illumination of the TPMS low tire pressure telltale. Your vehicle has also been equipped with a TPMS malfunction indicator to indicate when the system is not operating properly. The TPMS malfunction indicator is combined with the low tire pressure telltale. When the system detects a malfunction, the telltale will flash for approximately one minute and then remain continuously illuminated. This sequence will continue upon subsequent vehicle start-ups as long as the malfunction exists. When the malfunction indicator is illuminated, the system may not be able to detect or signal low tire pressure as intended. TPMS malfunctions may occur for a variety of reasons, including the installation of replacement or alternate tires or wheels on the vehicle that prevent the TPMS from functioning properly. Always check the TPMS malfunction telltale after replacing one or more tires or wheels on your vehicle to ensure that the replacement or alternate tires and wheels allow the TPMS to continue to function properly. The "CHECK TIRE PRESSURE" warning message and low tire pressure light (telltale) will come on each time the vehicle is started until the tires are inflated to the correct inflation pressure. The Tire and Loading Information label (tire information placard) shows the size of your vehicle's original tires and the correct inflation pressure for your vehicle's tires when they are cold. Your vehicle's TPMS can alert you about a low tire pressure condition but it does not replace normal tire maintenance. NOTICE: Do not use a tire sealant if your vehicle has Tire Pressure Monitors. The liquid sealant can damage the tire pressure monitor sensors. Page 18527 Low Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Low Pressure Switch Replacement (Non-HP2) Removal Procedure 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. Installation Procedure 1. Install the new O-ring seal to the switch. Notice: Refer to Fastener Notice. 2. Install the A/C low pressure switch to the accumulator. Tighten the switch to 6 N.m (53 lb in). 3. Connect the electrical connector to the A/C low pressure switch. 4. Leak test the fittings of the components using the J 39400-A. Page 11407 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. A/T - Control Valve/Solenoid Cleaning Information Valve Body: All Technical Service Bulletins A/T - Control Valve/Solenoid Cleaning Information INFORMATION Bulletin No.: 07-07-30-006B Date: March 02, 2010 Subject: Information on Control Solenoid Valve and Transmission Control Solenoid Module Assembly Cleaning Procedure for Rear Wheel Drive Six-Speed HYDRA-MATIC(R) Automatic Transmissions when MIL/DTCs Set Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 Equipped with Six Speed HYDRA-MATIC(R) 6L50, 6L80 or 6L90 Automatic Transmission (RPOs MYB, MYC, MYD) Supercede: This bulletin is being updated to add models and model years and to advise technicians that the control solenoid valve assembly cleaning procedure is no longer valid. Please discard Corporate Bulletin Number 07-07-30-006A (Section 07 - Transmission/Transaxle). The control solenoid (w/body and TCM) valve assembly cleaning procedure has been determined to be ineffective. This procedure will be removed from the scan tool and will be no longer available for use. Reference to this procedure will be removed from SI diagnostics and labor operation K9450 will be removed from the Labor Time Guide. Disclaimer Page 17367 X226 Inline Harness Connector End Views X226 Fuse Block Jumper Harness to Brake Clutch Harness (9L4) X227 Inline Harness Connector End Views X227 LED Indicator Harness to SPO Theft Harness (SPO Alarm) Page 3769 12. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: * Clutch material * Bronze slivers indicating bushing wear * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. 4. Install the oil pan and NEW gasket. Page 1952 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 4572 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt or felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Page 11076 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 23204 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Page 9363 Page 9360 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 5355 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 17029 Page 2441 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the connector position assurance (CPA) retainer. 3. Disconnect the engine wiring harness electrical connector (1) from the HO2S pigtail electrical connector. 4. Remove the HO2S pigtail electrical connector clip (2) from the frame. 5. Remove the HO2S (4). Page 2928 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Vehicle - Recreational (Dinghy) Towing Information Towing Information: Technical Service Bulletins Vehicle - Recreational (Dinghy) Towing Information Bulletin No.: 00-00-89-008F Date: July 28, 2006 INFORMATION Subject: Recreational (Dinghy) Towing Page 2051 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 4975 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 4488 11. Install the crankshaft balancer washer and bolt. Tighten the bolt to 95 N.m (70 lb ft). 12. Install the cooling fan. 13. Install the drive belt. Page 7825 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 7595 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 9051 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Trailer Brake Control Switch Replacement Trailer Brake Control Module: Service and Repair Trailer Brake Control Switch Replacement Trailer Brake Control Switch Replacement Page 11675 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 12530 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 7749 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 10447 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 17258 GM Engineering is seeing an increase in HVAC control head and actuator warranty where the component is fully functional when received. The root cause of the failure is intermittent wiring connections at the right hand BEC. Specifically, poor terminal tension of the 5V reference or Low Reference terminals in the X4 connector. Refer to the table. After the fault is removed. the actuators recover once commanded. Correction DO NOT REPLACE THE CONTROL HEAD. Use the following information to diagnose this condition: Page 21659 Antenna - Keyless Entry: Service and Repair Keyless Entry Antenna Replacement (Extended/Crew Cab) Keyless Entry Antenna Replacement (Extended/Crew Cab) Page 9086 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 2607 Page 6678 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 17311 X214 Inline Harness Connector End Views X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Page 8745 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 16995 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 12068 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 6606 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 5143 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 23960 Roof Marker Lamp - Right (U01) Page 20166 Page 5458 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 6760 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 10212 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 5432 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 9465 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 16655 Disclaimer Page 13284 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 16070 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 9501 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 9130 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.3L) Removal Procedure 1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Page 9705 Page 16641 Not all of the effects or driver notifications listed above have been experienced. However, the different effects and driver notifications may be caused by one of the wires in the IP harness being chafed or cut. Components on different lines in the list above are in different circuits. Due to the cause of the condition, and the positions of the wires in the IP harness, it is unlikely that more than one circuit will be affected by the condition. Upon investigation, the technician may find several DTCs set as current or in history. The technician may also find one or more blown fuses in the IP and underhood fuse blocks. The potential fuses are listed below: 60 amp MBEC1 (# 72) (Underhood) 30 amp AMP (# 40) (Underhood) 15 amp RDO (# 41) (Underhood) 10 amp IPC (# 46) (Underhood) 15 amp AIRBAG BATT (# 51) (Underhood) 10 amp DSM (Left side of IP) Cause The condition may be caused by one of the wires in the IP harness being chafed or cut on the parking brake pedal assembly. Five areas of potential contact have been identified and are shown. Body - Door Module/Switch Programming Information Door Module: Technical Service Bulletins Body - Door Module/Switch Programming Information INFORMATION Bulletin No.: 08-08-64-013 Date: August 19, 2008 Subject: Information on Reprogramming Replacement Door Modules/Switches Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK A large number of door modules are being returned through the Warranty Parts Center (WPC). The returned part analyses indicate that the door modules/switches are missing their respective software calibrations. Important: For step-by-step programming instructions, please refer to the Techline Information System (TIS) terminal. Select the appropriate controller - Driver Door Module (DDM) or Passenger Door Module (PDM). Any time a new door module is replaced, the module will require the updated software and/or calibration files using the TIS Service Programming System (SPS) application. Refer to Door Control Module Programming and Setup in SI. The information in this bulletin is being provided to help reduce the amount of door modules being returned. Check the wiring at the respective door module, the door "doc-n-loc" electrical connectors, software calibrations, and the specific hardware or wiring associated with the customer complaint (e.g., window regulator, outside mirror, door handle, etc.) prior to replacing any door module. Disclaimer Page 1457 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 10191 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 1925 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 9777 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 8207 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 17647 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 21579 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 21401 Roof Console Replacement Roof Console Replacement Page 10538 Page 17159 Junction Block - Right I/P X4 Page 8488 Knock Sensor: Connector Views Engine Controls Connector End Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Electronic Brake Control Module (JL4) Electronic Brake Control Module: Diagrams Electronic Brake Control Module (JL4) Electronic Brake Control Module (JL4) Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: Customer Interest Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 8580 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Replacement (JD9, JF3, JF7) Front Brake Caliper Replacement (JD9, JF3, JF7) Page 12164 Shift Solenoid 3 (SS3) Page 1129 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 3073 Electrical - No Start/No Crank/Int Electrical Operations Wiring Harness: All Technical Service Bulletins Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 486 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 20726 Page 15388 Page 11439 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 8024 * Minimum pedal value-At key-up the engine control module (ECM) updates the learned minimum pedal value. * Minimum throttle position (TP) values-At key-up the ECM updates the learned minimum TP value. In order to learn the minimum TP value, the throttle blade is moved to the closed position. * Ice break mode-If the throttle is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse width several times to the throttle actuator motor in the closing direction. * Battery saver mode-After a predetermined time without engine RPM, the ECM commands the battery saver mode. During the battery saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position. Reduced Engine Power Mode When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions: * Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control; however, the vehicle acceleration is limited. * Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control; however, the maximum throttle opening is limited. * Throttle default mode-The ECM will turn off the throttle actuator motor and the throttle will return to the spring loaded default position. * Forced idle mode-The ECM will perform the following actions: - Limit engine speed to idle by positioning the throttle position, or by controlling the fuel and spark if the throttle is turned off. - Ignore the accelerator pedal input. * Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator. Page 11950 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 20255 Hood Sensor/Switch (For Alarm): Diagrams Immobilizer Connector End Views Hood Ajar Switch (AP3/AP8) Page 9471 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 21522 Windshield Pillar Garnish Molding Replacement Windshield Pillar Garnish Molding Replacement Page 11611 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Entertainment System - DVD Screen Off After Ign. Cycle DVD Player: All Technical Service Bulletins Entertainment System - DVD Screen Off After Ign. Cycle INFORMATION Bulletin No.: 06-08-44-035C Date: August 04, 2009 Subject: Rear DVD Screen Off After Ignition Key is Cycled (Nav and Non-Nav Radios) Operating Instructions Models: 2007-2009 Buick Enclave 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra (Crew Cab Only), Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2007-2009 HUMMER H2, H2 SUT 2007-2009 Saturn OUTLOOK Supercede: This bulletin is being revised to add NAV radios and additional information. Please discard Corporate Bulletin Number 06-08-44-035B (Section 08 - Body & Accessories). Some customers may comment that the rear DVD screen will not turn back ON after an ignition key cycle. This is a normal operating characteristic and no repairs should be made to the DVD screen. Notice Some early build vehicles may operate in a different manner and may turn back on after an ignition key cycle. This operation may change when the vehicle's radio has been replaced or the software has been updated due to a service concern. Also, some customer's may compare their vehicle to an early built vehicle that is not operating to design intent. This bulletin is to advise that this is the design intent of the vehicle and no repair attempts should be performed to change this operation. Advise the customer to either: 1. Press the power (ON/OFF) button on the remote control to turn ON the DVD screen. 2. Eject and re-insert the disc into the radio. This method will restart the media from the beginning. 3. For NAV unit radios - press play on the CD/DVD tab. Disclaimer Page 11830 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 11861 Page 7194 Page 15748 10. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 9 N.m (80 lb in). 11. Connect the auxiliary battery positive cable electrical connector (2) to the engine wiring harness connector. 12. Install the relay (1) clip to the stud on the front of dash. 13. Install the mega fuse cover (3). 14. Install the auxiliary battery positive cable connector (1) to the UBEC. Page 1873 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 23593 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 1193 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2000 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Caution Caution: Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 24656 Wiper Motor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 1082 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 20519 Body Control Module (BCM) X4 Page 13634 Shift Solenoid: Service and Repair Allison - Automatic Transmission Control Valve Solenoid Replacement (PCS1 and PCS2) Control Valve Solenoid Replacement (PCS1 and PCS2) Removal Procedure 1. Remove the oil pan and transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the 2 bolts that fasten reverse signal pipe to the control valve assembly. Remove the reverse signal pipe. Important: * When the pressure control valve retaining bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall Page 8349 Page 612 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Diagrams Shock Sensor: Diagrams Theft Deterrent System Connector End Views Shock Sensor (SPO Alarm) Page 16181 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 12240 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 24496 Page 12846 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 1375 Passenger Door Switch (PDS) X3 (AN3/DL3) Page 14823 Shift Solenoid: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Page 11193 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 10873 Page 10060 Put unused material on the shelf for future use. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 19285 Page 1464 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 13846 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 21133 Endgate Emblem/Nameplate Replacement (TUF) Endgate Emblem/Nameplate Replacement (TUF) Page 9713 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 5590 Notice: During removal or installation, do not over extend the flex couple as internal damage may occur. 11. Remove the insulators (1) from the intermediate muffler assembly hangers and remove the muffler assembly. Pull the muffler assembly rearward until the flange is able to clear the front frame crossmember, and remove the muffler toward the front of the vehicle. Installation Procedure 1. If equipped with a 4.8L engine, perform the following steps, otherwise proceed to step 6. 2. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation. Notice: During removal or installation, do not over extend the flex couple as internal damage may occur. 3. With the aid of an assistant, position and install the muffler assembly. 4. Install the insulators (1, 2) to the front and rear muffler assembly hangers. Relay Replacement (Attached to Wire Harness) Power Distribution Relay: Service and Repair Relay Replacement (Attached to Wire Harness) Relay Replacement (Attached to Wire Harness) Removal Procedure 1. Locate the relay. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Important: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Interior - Front/Rear Drink Holder Won't Retain Drinks Drink Holders: Customer Interest Interior - Front/Rear Drink Holder Won't Retain Drinks Bulletin No.: 07-08-49-002 Date: January 24, 2007 TECHNICAL Subject: Front Floor Rear Console Cupholder Does Not Properly Retain Drink Containers (Install Updated Rear Console Cupholder Liner) Models: 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Denali, Sierra, Yukon Models with Center Console (RPO D07) Condition Some customers may comment that the front floor rear console cupholder can not retain drink containers while driving. Cause The current rear console cupholder mats do not have any retainers to properly hold the container while turning or accelerating, causing the container to tip over or fall out. Correction Replace the existing mats with the updated one piece cupholder liner using the procedure below: Open the front floor rear console cupholder assembly. Remove the existing two rear cupholder mats. Refer to the graphic above. Discard the old cupholder mats. Obtain an updated cupholder liner. The liner will have four outer tabs and inner retainers. Allison - Automatic Transmission Control Module: Service and Repair Allison - Automatic Transmission Transmission Control Module Replacement Page 24197 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Body Hinge Pillar Trim Panel Replacement Trim Panel: Service and Repair Body Hinge Pillar Trim Panel Replacement Body Hinge Pillar Trim Panel Replacement Page 3599 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 18326 GM Engineering is seeing an increase in HVAC control head and actuator warranty where the component is fully functional when received. The root cause of the failure is intermittent wiring connections at the right hand BEC. Specifically, poor terminal tension of the 5V reference or Low Reference terminals in the X4 connector. Refer to the table. After the fault is removed. the actuators recover once commanded. Correction DO NOT REPLACE THE CONTROL HEAD. Use the following information to diagnose this condition: Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 22222 Rear Seat Back Recliner Cover Replacement (Crew Cab with A68) Page 15303 Brake Drum: Specifications Maximum Allowable Diameter .............................................................................................................................................................. 296.5 mm 11.673 in Maximum Allowable Radial Runout ........................................................................................................................................................ 0.06 mm 0.0024 in Maximum Allowable Scoring ................................................................................. ....................................................................................... 1.5 mm 0.06 in Page 13140 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 13788 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 3052 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Reluctor Ring Replacement Crankshaft Position Sensor Reluctor Ring Replacement Tools Required j 5590 Rear Pinion Bearing Race Installer Removal Procedure 1. Remove the engine front cover. 2. Remove the crankshaft position (CKP) sensor reluctor ring. Installation Procedure Page 4330 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 6226 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 21806 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 11110 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 23002 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 19320 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 24643 4. Install a 3-amp fused jumper wire between the signal circuit terminal 3 (1) and ground. Verify that the scan tool Wiper Park Switch parameter is Active. - If not an active value, test the signal circuit for an open/high resistance. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the open wire. 5. If all circuits test normal, replace the windshield wiper motor and do NOT perform the following repair. Do not proceed on with this bulletin. Wiring Repair - To correct this concern relocate the wiper motor park switch ground circuit as follows: Important Do Not replace the wiper motor at this time. 1. Disconnect the wiper motor connector and remove any tape/conduit 75-100 mm (3-4 in) from the connector end. 2. Locate and cut circuit 1851 (pin 2 Black/White wire) approximately 50 mm (2 in) from the wiper motor connector. 3. Using 18 gauge (0.8 metric) Black wire, route the new park switch ground circuit through the front of dash grommet (1). 4. Using a Salmon Duraseal splice sleeve, refer to Splicing Copper Wire Using Splice Sleeves in SI. Splice the new wire onto circuit 1851 terminal 2 that is still attached to the wiper motor connector. Use electrical tape to tape and secure the other cut end of circuit 1851 into the wiper motor harness. 5. Attach the new park switch ground circuit along side the wiper motor harness using zip ties or electrical tape, up to the front of dash grommet. 6. Cut the other end of the new park switch ground circuit long enough to reach the new ground location shown below. 7. Install the appropriate size ring terminal to the wire and attach to the ground stud (2) using the existing nut. 8. Reinstall the cowl cover following the Air Inlet Grille Panel Replacement procedure in SI. 9. Verify wiper motor operation. If the concern is still present, proceed to BCM-Replace below. BCM-Replace Replace the BCM and program if the concern is still not repaired. Refer to Body Control Module Replacement and program in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 2604 Vehicle Zoning Strategy Truck Zoning Page 15954 Auxiliary Power Outlet: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure Page 2818 Page 3605 Step 1 - Step 7 Page 22651 Seat Adjuster Switch - Passenger (AG2 -AN3) Seat Adjuster Switch - Passenger (AN3) Page 8930 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 6307 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 19087 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat belt pretensioner from the vehicle. 5. When carrying a seat belt pretensioner to the deployment area, keep fingers clear of the seat belt webbing. 6. Clear a space on the ground about 1.85 m (6 ft) in diameter for deployment of the seat belt pretensioner. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. 7. Make sure no loose or flammable objects are in the area. 8. Place the J 39401-B in the center of the cleared area. 9. Fill the fixture plastic reservoir with water or sand. Page 946 Engine Control Module: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 24738 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 20962 For vehicles repaired under warranty, use the table. Disclaimer Page 13795 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 14289 1. Position the boot (1) so that it is seated properly in the groove (2) in the wheel drive shaft (3). 2. Install the small boot clamp (2) on the boot (1). 3. Using the J 35910 , a breaker bar, and a torque wrench (1), close the boot clamp (2) until the gap (3) measures 2.15 mm (0.085 inch). Page 11321 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9068 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10579 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 24179 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 5892 Page 24064 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (without RPO SLT) Fog Lamp Switch Replacement (without RPO SLT) Page 892 Page 12599 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 4152 Page 22916 Page 2397 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 2086 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7221 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 408 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement Page 13779 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 8485 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 12575 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 11574 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 13565 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 8895 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 8533 Page 6900 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 20549 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Side Bracket Replacement (GMC) Front Bumper Fascia Side Bracket Replacement (GMC) Page 22518 Page 6367 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 12451 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 987 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 2413 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 12741 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 14274 8. Install the boot (1) and the boot clamp (2) on the tripot housing (3). 9. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-98 and secure the base in a vise. 10. For the 2500, 3500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. 11. Position the tripot end of the wheel drive shaft assembly into the base of the J 36652-98 for the 1500 models or J 36652-1 for the 2500, 3500 models. 12. Install the top half of the J 36652-98 for the 1500 models or J 36652-1 for the 2500, 3500 models. 13. Align the boot clamp (2) and the clamp. Important: Hand tighten the bolts until the bolts are snug. 14. Insert the bolts. 15. Align the tripot boot, tripot housing, and the boot clamp. Important: Alternate between the bolts until both sides of the top half of the tool touch the bottom half. 16. Tighten each bolt 180 degrees at a time. 17. Loosen the bolts and remove the halfshaft assembly from the tool. Page 12794 Shift Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Adjustments Front Door Striker: Adjustments Door Lock Striker Adjustment To determine if striker adjustment is required, proceed as follows: 1. Make certain the door is properly aligned within the door opening before proceeding with the striker adjustment. 2. Close the door onto the striker and note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note the closing effort to fully engage the latch. 3. Using a soft marker, mark around the striker for reference of the original position. Loosen the striker. 4. Move the striker to eliminate drag on the striker and door latch and to achieve the proper door position within the door opening. Start with the up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for the proper door seal engagement making sure the door closing efforts are correct. Notice: Refer to Fastener Notice. 5. Tighten the striker-to-body bolts. Tighten the door striker-to-body bolts to 27 N.m (20 lb ft). Page 5592 10. Install the insulator (1) to the intermediate muffler assembly hanger. Notice: Refer to Fastener Notice. 11. Install the catalytic converter to exhaust muffler nuts. Tighten the nuts to 45 N.m (33 lb ft). 12. Return the spare tire to the original position. 13. Lower the vehicle. Page 211 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 17351 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Page 9271 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 3479 Alignment: Description and Operation Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid - A/T: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Fluid and Filter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket. 5. Remove the catalytic converter. 6. Remove the oil pan bolts from the front and sides of the pan only. 7. Loosen the rear oil pan bolts approximately 4 turns. 8. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain. 9. Remove the remaining oil pan bolts. 10. Remove the oil pan and the gasket. 11. Grasp firmly while pulling down with a twisting motion in order to remove the filter. Recall - Heated Windshield Washer Module Short Circuit Technical Service Bulletin # 10153B Date: 100720 Recall - Heated Windshield Washer Module Short Circuit SAFETY Bulletin No.: 10153B Date: July 20, 2010 Subject: 10153A - Heated Windshield Washer Module Short Circuit - Permanently Disable and Remove Module Models: 2006-2009 Buick Lucerne 2008-2009 Buick Enclave 2006-2009 Cadillac DTS 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2009 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2006-2009 HUMMER H2 2007-2009 Saturn OUTLOOK Equipped with Heated Washer Fluid System (RPO XA7/CHW) Supercede: This bulletin is being revised to include a note in the service procedure for dealers to confirm that the customer is aware that this safety recall is being performed on their vehicle prior to performing the repair. A T labor code for customers who refuse to have the recall performed. This labor code will NOT close the recall. If a customer refuses to have the recall performed, dealers are to provide the customer with a copy of the "Notice to Customer" document contained in this bulletin, record on the repair order "customer declined recall repair" and, if possible, have the customer sign the repair order. Request that the letter be placed in the vehicle glovebox for future reference by subsequent owners. If at a later date the customer, or a new owner, decides to have the recall performed, perform the repair and submit the claim using the appropriate V labor code. A clarification in the Q&A; regarding proof of vehicle ownership. Please discard all copies of bulletin 10153A, issued July 2010. Condition General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (RPO XA7/CHW). A recall was implemented on some vehicles in 2008 to add a fuse to the HWFS control circuit harness to address the potential consequences of a printed circuit board electrical short. However, there have been new reports of thermal incidents on HWFS modules after this improvement was installed. These incidents resulted from a new failure mode attributed to the device's thermal protection feature. Their significance varies from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. Correction Dealers/retailers are to permanently disable and remove the heated washer fluid system and compensate the customer for the loss of the feature. Vehicles Involved Involved are certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (RPO XA7/CHW), and built within these VIN breakpoints: Page 20888 Disclaimer Technical Service Bulletin # 09-08-64-023 Date: 090603 Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Page 7399 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20839 Page 4242 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 22099 For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4093 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 10587 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 23674 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 13513 Shift Solenoid: Specifications 6L50/6L80/6L90 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Shift Solenoid Valve State and Gear Ratio Body - Sticking/Binding Door Mounted Seat Switches Power Seat Switch: Customer Interest Body - Sticking/Binding Door Mounted Seat Switches TECHNICAL Bulletin No.: 09-08-50-011A Date: April 13, 2011 Subject: Sticking/Binding Door Mounted Seat Switches (Align Switch) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali All Equipped with RPOs AN3, KA1, KB6 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-50-011 (Section 08 - Body and Accessories). Condition Some customers may comment that the door mounted memory/ heated/ cool seat switch buttons are sticking or binding. Cause This condition may be caused by the switch being out of alignment in the bezel, creating a hard contact between the switch button and the inside release handle bezel. Correction 1. Remove the door trim. Refer to Front Side Door Trim Panel Replacement in SI. 2. Loosen both screws (1) holding the switch to the inside release handle bezel. 3. Using a flat-bladed tool (1), carefully shift the position of the switch to create a nominal gap all around its perimeter within the bezel. Tighten the two screws holding the switch. Page 23794 For vehicles repaired under warranty, use the table. Disclaimer Electrical - Aftermarket Fuse Warning Fuse: All Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Page 6596 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 14283 18. Pinch the new swage ring (2) slightly by hand to distort it into an oval shape. 19. Slide the distorted swage ring (2) over the large diameter of the boot (1). Important: Be sure that the retaining ring side of the CV joint inner race faces the halfshaft bar (3) before installation. 20. Slide the CV joint (4) onto the halfshaft bar (3). The retaining snap ring inside of the inner race engages in the halfshaft bar groove with a click when the CV joint (4) is in the proper position. 21. Pull on the CV joint (4) to verify engagement. 22. Slide the large diameter of the CV joint boot (1), with the large swage ring (2) in place, over the outside edge of the CV joint outer race (4). 23. Clamp the CV joint boot (2) tightly to the CV joint outer race (1) with the large swage ring (4), using the following procedure: 24. For the 1500 models, assemble the bolts and the support plate to the base of the J 36652-1 and secure the base in a vise. For the 2500 and 3500 models, use the J 36652-2. 25. Position the CV joint end (outboard end) of the halfshaft assembly in the bottom half of J 36652-1 or J 36652-2. Page 22240 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 3918 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 10597 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 8632 Interior - Front Seat Armrest Bolt Accessory Cover Arm Rest: All Technical Service Bulletins Interior - Front Seat Armrest Bolt Accessory Cover Bulletin No.: 07-08-50-014 Date: June 20, 2007 INFORMATION Subject: Front Center Seat Armrest Bolt Accessory Cover Available for Service Use Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Driver and Passenger Front Seat Split, Full Feature Center (RPO AZ3) The front center seat armrest bolt accessory cover is now available for service as a separate part. The front center seat armrest bolt accessory cover was formerly available as part of the entire front center seat assembly. DO NOT replace the entire front center seat assembly. If the front center seat armrest bolt finish cover (1) is required, use the following steps below: Open the passenger door. Position the passenger front seat track all the way back. Tilt the passenger seat back to the full tilt back position. Remove the right front center seat armrest hinge cover plastic retainer with a door trim tool. Use a screwdriver to release the inner tabs inside the right front center seat armrest hinge finish cover. Remove the right front center seat armrest hinge finish cover. Pull outward on the front portion of the center seat armrest bolt accessory cover to release the metal retaining clip. Remove the front center seat armrest bolt accessory cover. Remove the metal clip from the old center seat armrest bolt accessory cover. Install the metal clip onto the new front center seat armrest bolt accessory cover. Install the new front center seat armrest bolt accessory cover to the armrest assembly and firmly seat the metal clip. Install the right front center seat armrest hinge finish cover. Install the plastic retainer. Tilt the passenger seat back to the up position. Page 14675 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 6544 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 597 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 2267 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 9262 Service and Repair Horn Switch: Service and Repair Horn Switch Replacement Page 9225 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 2785 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 2174 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Tank Pressure Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 22249 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8753 Page 6149 Page 9009 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Notice: Refer to Fastener Notice. 2. Install the accelerator pedal bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: Page 18156 Wheel Hub: Service and Repair Front Wheel Hub, Bearing, and Seal Replacement (1500) Page 7852 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 11220 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 10658 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Notice: Refer to Fastener Notice. 4. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 N.m (80 lb in). 5. Install the fuel/EVAP line clip nut (2). Tighten the nut to 20 N.m (15 lb ft). 6. Remove the caps from the fuel and EVAP lines. 7. Connect the chassis EVAP line quick connect fitting to the EVAP canister. 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Page 4792 Disclaimer Page 8934 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 14095 1. Locate the terminal position assurance (TPA) as shown. Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 2. Use a small flat blade tool to push the TPA until it bottoms out. 3. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Note If the female terminal(s) must be replaced, it is part number 22124472200. It is located in Yazaki tray number 12 in the J-38125 Terminal Repair Kit. Interior - Lint Accumulation On Ebony Colored Seats Head Rest: Customer Interest Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 21756 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 5196 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 8150 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 7712 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 2078 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 15456 Disclaimer Page 11075 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 16463 Page 11931 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 15396 Page 5853 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 13154 Control Module: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Control Module Replacement Page 2061 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 4045 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 1915 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11899 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Auxiliary Body Control Module Replacement Body Control Module: Service and Repair Auxiliary Body Control Module Replacement Auxiliary Body Control Module Replacement Page 1661 Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 2376 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 16605 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Specifications Idle Speed: Specifications Information not supplied by the manufacturer Page 4226 Frequently Asked Questions Disclaimer Page 11594 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2455 Page 3936 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8564 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 14255 Note: Install the rear wheel bearing adjuster nut by hand. 16. Using the J 2222-C wrench , adjust the rear wheel bearings. 17. Install the rear axle shaft. 18. Install the brake caliper bracket. 19. Install the tire and wheel assembly. 20. Inspect and add axle lubricant to the axle housing, if necessary. 21. Remove the supports and lower the vehicle. Page 17901 Ensure that the fingers for the spring compressor are properly adjusted on the top of the front suspension mount. Position the shock absorber assembly (3) in the J 45400 (2) so that the fingers are properly seated on the top of the front suspension strut mount (1). Note the orientation of the upper spring seat, spring, and the shock before the they are to be removed. This will aid in the proper align during the installation procedure. Using the J 45400 (1), compressed the front spring (2). Remove and discard the nut (3) from the shock (4). DO NOT reuse the nut, use NEW only. Remove the front suspension shock absorber (2), and the front spring lower insulator (1). Page 2074 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 4966 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 2444 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer. 3. Disconnect the HO2S pigtail electrical connector (5) from the engine wiring harness electrical connector (4). 4. Remove the HO2S (2). Installation Procedure Page 9474 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 11308 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Locations Daytime Running Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 9460 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 6408 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 10989 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 1099 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 24219 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 11453 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 9916 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 14881 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 12151 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 10550 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 8473 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 9650 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 9921 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 3194 1 - Door Frame 2 - Window Switch - Left Rear (ABV) 3 - Speaker - Left Rear Door 4 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 5 - Window Motor - Left Rear (ABV) Right Rear Door (Extended Cab) Page 17386 X408 Inline Harness Connector End Views X408 Chassis Harness to Rear Bumper Harness (UD7) X414 Inline Harness Connector End Views Page 21123 Body Emblem: Service and Repair Endgate Emblem/Nameplate Replacement (Cheyenne or Silverado) Endgate Emblem/Nameplate Replacement (Cheyenne or Silverado) Page 9648 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 11279 View of the connector when released from the component. View of another type of Micro 64 connector. Page 9104 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Lighting - Turn Signals Have Increased Flash Rate Body Control Module: Customer Interest Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2165 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 22093 3. Inspect the wiring harness for damage or improper routing near drivers side rear screw hole. Refer to the above graphic (callout # 1 shows proper routing callout # 2 indicates improper routing). 4. Repair the wiring harness as necessary. If the wiring harness is not damaged refer to SI for diagnosis and repair of the system. 5. Install the DVD screen and the four retaining screws. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4687 Notice: Proper lower intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifold bolts using the 3 step method. Failing to do so may distort the crankshaft bearing bore alignment and cause damage to the crankshaft bearings. Notice: Refer to Fastener Notice. 10. Tighten the intake manifold - lower bolts in the sequence shown. 1. Tighten the bolts a first pass to 3 N.m (27 lb in). 2. Tighten the bolts a second pass to 12 N.m (106 lb in). 3. Tighten the bolts a final pass to 15 N.m (11 lb ft). 11. Slide the P/S pump bracket rearward. 12. Install the bolts and the nut for the P/S pump bracket. 13. Install the P/S pump rear bracket front nut. 14. Tighten the P/S pump rear bracket nut. Tighten the bolts and nuts to 41 N.m (30 lb ft). 15. Install the drive belt. 16. Install the water pump inlet hose. 17. Position the water pump inlet hose clamps. Service and Repair Power Take-Off Switch: Service and Repair Power Take-Off Switch Replacement Page 17161 Junction Block - Right I/P X6 Interior - Front Seat Armrest Bolt Accessory Cover Arm Rest: All Technical Service Bulletins Interior - Front Seat Armrest Bolt Accessory Cover Bulletin No.: 07-08-50-014 Date: June 20, 2007 INFORMATION Subject: Front Center Seat Armrest Bolt Accessory Cover Available for Service Use Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Driver and Passenger Front Seat Split, Full Feature Center (RPO AZ3) The front center seat armrest bolt accessory cover is now available for service as a separate part. The front center seat armrest bolt accessory cover was formerly available as part of the entire front center seat assembly. DO NOT replace the entire front center seat assembly. If the front center seat armrest bolt finish cover (1) is required, use the following steps below: Open the passenger door. Position the passenger front seat track all the way back. Tilt the passenger seat back to the full tilt back position. Remove the right front center seat armrest hinge cover plastic retainer with a door trim tool. Use a screwdriver to release the inner tabs inside the right front center seat armrest hinge finish cover. Remove the right front center seat armrest hinge finish cover. Pull outward on the front portion of the center seat armrest bolt accessory cover to release the metal retaining clip. Remove the front center seat armrest bolt accessory cover. Remove the metal clip from the old center seat armrest bolt accessory cover. Install the metal clip onto the new front center seat armrest bolt accessory cover. Install the new front center seat armrest bolt accessory cover to the armrest assembly and firmly seat the metal clip. Install the right front center seat armrest hinge finish cover. Install the plastic retainer. Tilt the passenger seat back to the up position. Page 5944 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 11791 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 14226 12. Remove the pinion oil seal. Use a suitable seal removal tool. Do not damage the housing. Installation Procedure 1. Install a new pinion oil seal using the J 22388. 2. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the splines of the pinion yoke. 3. Install the pinion yoke. Align the marks made during removal. Notice: Refer to Pinion Flange/Yoke Installation Notice. Page 6918 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 5957 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 16662 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 3038 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 11573 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 16859 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2038 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 4754 8. Remove and discard the CKP sensor O-ring seal. 9. Disconnect the engine wiring harness electrical connector from the camshaft position (CMP) sensor wiring harness jumper. Page 24560 4. Connect the other end of the jumper harness into the connector (1) at the windshield solvent heater module. 5. Ensure that the jumper harness and windshield solvent heater module wire harness are routed and secured properly. 6. For vehicles that previously had the 60 amp heated windshield washer fuse removed, retrieve the fuse from the glove compartment and reinstall the fuse. Important It may take up to 40 seconds for the heated washer fluid system to dispense heated fluid. 7. Verify the operation of the heated washer fluid system. Ensure the system dispenses heated fluid. Claim Information - GM, Saturn Canada Only Submit a Product Recall Claim with the information indicated below: Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission. Claim Information - Saturn US Only 1. To receive credit, submit a claim with the information below: * The parts allowance should be the sum total of the current SSPO retailer net price plus 40% of all parts required for the repair. Customer Notification - For US and Canada General Motors notified customers of this recall on their vehicle in September 2008. Customer Notification - For Export Letters were sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Page 6712 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 141 Parking Assist Control Module: Locations Object Detection Component Views Under the Front Seats 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Page 3998 1 - Battery - Right 2 - Fuse Holder - Underhood 3 - X127 4 - X108 5 - X107 6 - X123 (PTO) 7 Fuse Block - Underhood 8 - X109 9 - Battery - Left (6A6/TP2) 10 - Engine Control Module (ECM) 11 - Transmission Control Module (TCM) Fuse Block Jumper Harness (9L4) Page 9785 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Diagrams Map Light: Diagrams Lighting Systems Connector End Views Courtesy/Reading Lamps - Front Courtesy/Reading Lamps - Rear (Extended Cab/Crew Cab) Page 23901 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 9461 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 480 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. A/C - Indicators Flashing (Normal Condition) Control Assembly: All Technical Service Bulletins A/C - Indicators Flashing (Normal Condition) Bulletin No.: 07-01-38-003 Date: June 12, 2007 INFORMATION Subject: Information for Vehicles with HVAC Control Module A/C And Recirculation Indicators Flashing Models: 2008 Buick Enclave 2007-2008 Cadillac Escalade Models 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2007-2008 GMC Acadia, Sierra, Yukon Models 2007-2008 Pontiac Torrent 2008 HUMMER H2 2007-2008 Saturn OUTLOOK 2008 Saturn VUE Condition/Concern Some customers may comment that the Air Conditioning (A/C) indicator on the Heating Ventilation and Air Conditioning (HVAC) Control Module flashes then turns off after they press the A/C button. Others may comment that the Recirculation indicator on the HVAC Control Module flashes then turns off after they press the Recirculation button. This is normal operation for the HVAC Control Module and indicates that the A/C or Recirculation function is not available at this time. Reasons that the A/C may not be available (calibrated values vary by program) are listed below. Consult the appropriate vehicle Service Information (SI) for detailed HVAC Description and Operation: Ambient Air Temperature is too low (if equipped with Ambient Air Temperature Sensor) Vehicle voltage less than 9.5 volts Refrigerant Pressure too low Refrigerant Pressure too high Engine Coolant Temperature too high Engine is not in RUN HVAC Control Head is in the OFF position Reasons Recirculation may not be available: Mode switch in Floor, Defog or Defrost mode. The reason(s) A/C is currently disabled can be viewed with a Tech 2(R) by navigating to HVAC Data display and viewing the "A/C Permission" parameter. Recommendation/Instructions Do not replace the HVAC Control Module for a flashing A/C Indicator or flashing Recirculation Indicator, as this is normal operation. Disclaimer Page 9184 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 15858 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Page 14572 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). Tighten the bolts to 10 N.m (89 lb in). Ball Check Valves 5. Install the 7 checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Page 2207 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 2504 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 20550 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Outer Support Replacement (GMC) Front Bumper Fascia Outer Support Replacement (GMC) Page 4940 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 10583 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 17026 Page 193 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11550 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 17377 X305 Body Harness to Passenger Seat Harness (-AN3) Page 16727 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 11326 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 3136 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 12204 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 544 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 15907 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 5043 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 19223 Seat Position Sensor: Service and Repair Inflatable Restraint Seat Position Sensor Replacement Page 3970 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 12839 View of the connector when released from the component. View of another type of Micro 64 connector. Page 883 Body Control Module (BCM) X2 Page 8947 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 1879 Page 4028 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 9752 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 13028 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Locations Accelerator Pedal Position Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 7097 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 9410 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 21594 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 9906 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 16999 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 2762 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 15695 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Ring Replacement Rear Wheel Speed Sensor Ring Replacement Tools Required * J 8092 Driver Handle * J 21128 Axle Pinion Oil Seal Installer * J 23690 Bearing Installer * J 2619-01 Slide Hammer * J 45857 Tone Wheel and/or Bearing Remover * J 45860 Tone Ring Installer Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. 3. Remove the rear wheel speed sensor. 4. Remove the rear axle housing cover. 5. Remove the axle shaft. 6. Remove the axle shaft seal, the bearing and the wheel speed sensor ring from the axle housing using the J 45857 (1) and the J 2619-01 (2). Installation Procedure 1. Install the wheel speed sensor ring using the J 45860 (1) and the J 8092 (2). 2. Drive the wheel speed sensor ring into the axle housing until the tool bottoms against the tube. Electrical - 'No Trailer Connected' Message On DIC Trailer Brake Control Module: All Technical Service Bulletins Electrical - 'No Trailer Connected' Message On DIC TECHNICAL Bulletin No.: 09-05-22-004 Date: November 05, 2009 Subject: No "Trailer Connected" Message on Driver Information Center (DIC) at Startup When Trailer is Connected (Reprogram ITBCM) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Equipped with Integrated Trailer Brake (RPO JL1) Condition Some customers may comment that when they connect their trailer, with the engine off, and after they start the engine, the Trailer Connected message is not displayed on the DIC. With the engine running, if the trailer connector is cycled, the vehicle will detect the trailer and display Trailer Connected. This concern should only affect trailers equipped with trailer brakes on a single axle. Cause The trailer brake control system is only compatible with trailers equipped with electric trailer brakes. The system will not work or detect trailers equipped with any other types of brakes such as surge, air or electric-over-hydraulic trailer brake systems. When a trailer is connected, the Trailer Brake Control Module (TBCM) performs a test to determine if the trailer is equipped with electric trailer brakes. If the trailer wiring or electric trailer brake magnets have additional resistance (caused by poor connections, corrosion, improper splices, etc.), the TBCM may not be able to detect the trailer. Correction A revised calibration has been developed to address these issues. Reprogram the Integrated Trailer Brake Control Module (ITBCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Refer to Trailer Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2847 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 21823 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 6989 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 12281 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 5905 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 3934 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 9102 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 23586 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 4704 24. Position the EVAP canister purge solenoid tube, and connect the tube quick connect fitting (1) to the EVAP purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service. 25. Connect the following electrical connectors: * The EVAP canister purge solenoid valve (1) * The MAP sensor Page 10678 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip (1) from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 5661 A list of involved vehicles currently in dealer inventory is attached to the Administrative Message (US) or Dealer Communication (Canada) used to release this bulletin. Customer vehicles that return for service, for any reason, and are still covered under the vehicle's base warranty, and are within the VIN breakpoints provided below, should be checked for vehicle eligibility in the appropriate system listed below. Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved. Service Procedure Important: Technicians may experience slow performance using the TIS2 web application when reprogramming the vehicle to correct the condition. Technicians may notice the slower application performance from mid-morning until late afternoon. To assist in improving performance and reduce programming time, it is recommended to complete the bulletin procedure on customer vehicles first. Vehicles in inventory should be programmed during off peak hours if slow performance is experienced. Important: The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and the Techline Information System (TIS) terminal with the calibration update. Use TIS 2 Web version 2.0 for 2007 (available on 02/04/07) and on TIS DVD version 2.0/2007 or later, that was mailed to dealers on 02/14/2007. If you cannot access the calibration, call the Techline Customer Support Center. Notice: Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use jumper cables from an additional battery. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed. The ignition switch must be in the proper position. The Tech 2(R) prompts you to turn ON the ignition, with the engine OFF. DO NOT change the Page 15413 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement (JH6, JH7) Brake Pressure Modulator Valve Replacement (JH6, JH7) Page 5433 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 11256 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 11694 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Fuse Block - I/P, Top View Fuse: Application and ID Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Label Page 21571 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 15240 Page 3774 Page 7134 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16734 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 14233 15. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3-5 lb in) greater than the rotating torque recorded during removal. 16. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 17. Determine the selective shim thickness for the pinion gear bearing retainer. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Pinion Depth Adjustment (10.5 Inch Axle). 18. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to sealing surface of the pinion gear bearing retainer. 19. Install the selective shim. Align the tab on the shim with the unmachined surface of the pinion gear bearing retainer. 20. Apply sealant, GM P/N 1052942 (Canadian P/N 10953466) or equivalent, to surface of the selective shim. 21. Install the pinion gear bearing retainer. 22. Install the pinion gear bearing retainer bolts. Tighten the pinion gear bearing retainer bolts to 88 N.m (65 lb ft). 23. Measure the rotating torque of the pinion and the ring gear. Compare this measurement with the rotating torque recorded during removal. The rotating torque of the pinion and the ring gear should be between 3.9-6.2 N.m (30-55 lb in) for new bearings or 2.8-5.6 N.m (25-50 lb in) for used bearings. 24. If the rotating torque of the pinion and the ring gear is not within specifications, adjust the preload of the pinion or the differential side bearings as necessary. Page 12397 Transmission Speed Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Page 23718 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9297 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 11774 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Locations Fuel Pressure Sensor/Switch: Locations Engine Controls Component Views Near the Fuel Tank 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (- Diesel) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Line Pressure Sensor (-LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly - Front (Gas) Specifications Crankshaft Main Bearing: Specifications Crankshaft Bearing Cap Bolt - Preferred Method First Pass ............................................................................................................................................. ..................................................... 20 N.m 15 lb ft Final Pass ............................................................. ........................................................................................................................................... 73 degrees Crankshaft Bearing Cap Bolt ............................................................................................................... ........................................................ 105 N.m 77 lb ft Crankshaft Main Bearing Clearance #1 - Production ........................................................................................................ 0.02-0.05 mm 0.0008-0.0020 in Crankshaft Main Bearing Clearance #2, #3, and #4 - Production ................................................................................. 0.028-0.058 mm 0.0011-0.0023 in Crankshaft Main Bearing Clearance #1 - Service .......................................................................................................... 0.0254-0.05 mm 0.0010-0.0020 in Crankshaft Main Bearing Clearance #2, #3, and #4 - Service ....................................................................................... 0.025-0.063 mm 0.0010-0.0025 in Page 8388 Vehicle Zoning Strategy Truck Zoning Page 19284 Page 4079 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 5784 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 23856 Page 7078 Page 19116 Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Crew Cab +ASF) Page 2442 Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (4). Tighten the sensor to 42 N.m (31 lb ft). 3. Install the HO2S pigtail electrical connector clip (2) to the frame. Page 8430 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Drivetrain - Bump/Clunk Noise at Stop Or From Launch Drive/Propeller Shaft: All Technical Service Bulletins Drivetrain - Bump/Clunk Noise at Stop Or From Launch TECHNICAL Bulletin No.: 09-04-17-002E Date: January 14, 2011 Subject: Bump Feel/Clunk Noise at Stop or from Launch (Clean/Lubricate Propeller Shaft Slip Yoke Splines) Models: 2007-2008 Chevrolet Avalanche, Suburban 2007-2009 Chevrolet Tahoe 2007-2010 Chevrolet Silverado (New Body Style) with Single-Piece Propshafts 2007-2008 GMC Yukon XL 2007-2009 GMC Yukon 2007-2010 GMC Sierra (New Body Style) with Single-Piece Propshafts All Equipped with 4L60 Automatic Transmission (RPO M30) and 2WD Attention: This bulletin contains a procedure to clean/lubricate the slip yoke splines and replace the slip yoke, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the slip yoke. Supercede: This bulletin is being revised to update the warranty statement. Please discard Corporate Bulletin Number 09-04-17-002D (Section 04 - Driveline/Axle). Condition Some customers may comment that the vehicle has a bump feel or a clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind. Cause This condition may be caused by a slip/stick condition in the interface between the rear propshaft slip yoke and the transmission output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transmission while the vehicle rebounds slightly backward after stopping its momentum and create this condition. Correction Note Do not use the grease from this bulletin for lubrication of the slip yoke splines on 2WD MYC 6 Speed Transmissions or any 4WD vehicles. The output shaft in a 2WD MYC 6 Speed Transmissions or a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transmission or the transfer case and mixing with the fluid inside. The new grease is not compatible with the automatic transmission fluid (ATF) and can cause damage if mixed. Please refer to Corporate Bulletin Number 09-04-21-003B for repairing the bump feel or clunk noise condition on 4WD vehicles. Note A bump feel or noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic. Verify the customer's concern. Clean/Lubricate Slip Yoke Splines 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 2. Inspect the rear slip yoke splines on the drive shaft. 3. Clean the slip yoke splines with brake cleaner or equivalent and a shop towel. 4. Assure the yoke is free of rust or other foreign material. 5. Lubricate the slip yoke spline with grease, P/N 19257121 (in Canada, 19257122), using a brush or swab to completely cover the entire spline with a light coating of grease. Page 16156 Page 9554 1. Install a NEW MAP sensor seal to the MAP sensor, if necessary. 2. Install the MAP sensor (2) to the upper intake manifold. Notice: Refer to Fastener Notice. 3. Install the MAP sensor bolt (1). Tighten the bolt to 10 N.m (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the MAP sensor. Page 21255 Close the passenger door. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10928 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 13805 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 22396 1 - Heated Seat Element - Driver Back 2 - Heated Seat Element - Driver Cushion Seat Heating Elements - Passenger (AN3) Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Page 3587 Disclaimer Page 9480 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Service and Repair Accumulator: Service and Repair Accumulator Assembly, Spacer Plate, and Gaskets Tools Required * J 25025-B Dial Indicator Post and Guide Pin Set * J 36850 Transjel Lubricant Removal Procedure 1. Remove the transmission filter. Important: The 1-2 accumulator can be removed without removing the valve body. 2. Remove the valve body. 3. Remove the accumulator cover bolts. 4. Remove the 1-2 accumulator cover. Important: regular production option (RPO) M33 transmissions do not use a 1-2 accumulator spring inner (104). 5. Remove the 1-2 accumulator cover (57) and pin. 6. Disassemble the 1-2 accumulator assembly (54, 56, 57, 104). 7. Inspect the 1-2 accumulator springs for cracks. Page 21591 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 7642 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 6064 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 15700 Yaw Rate Sensor: Diagrams Yaw Rate and Lateral Acceleration Sensor (JL4) Yaw Rate and Lateral Acceleration Sensor (JL4) Page 4692 33. Connect the engine wiring harness electrical connector (2) to the throttle body. 34. Position the heater inlet and outlet hoses. 35. Open the heater inlet hose clamp and install the hose to the water pump. 36. Open the heater outlet hose clamp and install the hose to the intake manifold. Page 13180 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Rear Seat Belt Retractor Replacement (Crew Cab) Seat Belt Retractor: Service and Repair Rear Seat Belt Retractor Replacement (Crew Cab) Rear Seat Belt Retractor Replacement (Crew Cab) Page 2716 Page 2805 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 1844 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 573 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 7876 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 19991 Page 8521 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 12593 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 7590 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 9926 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 14914 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4832 1. Ensure that the spark plug washer is positioned correctly. 2. Inspect the spark plug gap. Adjust the gap as needed. 3. Install the spark plug into the cylinder head by hand. (left side shown, right similar). Notice: Refer to Fastener Notice. 4. Tighten the spark plug. Tighten the plug to 15 N.m (11 lb ft). 5. If reinstalling the old spark plug wires, apply dielectric grease GM PN 12345579 (Canadian PN 10953481), or equivalent to the inside the spark plug wire boots. 6. Install the appropriate spark plug wire boot(s) (2) to the spark plug. (left side shown, right similar). Page 9730 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 13597 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 7617 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 3132 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 2109 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Sunshade Anchor Replacement Sun Visor: Service and Repair Sunshade Anchor Replacement Sunshade Anchor Replacement Page 9649 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20383 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 2250 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 8307 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 441 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11115 Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 13004 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 8535 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 24615 Wiper Arm: Service and Repair Windshield Wiper Arm Replacement (HD) Windshield Wiper Arm Replacement (HD) Page 2215 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 2157 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 20660 The DIC displays the timer in the following format: XX: XX:XX: The first XX represents hours elapsed, the second XX represents minutes elapsed, and the third XX represents seconds elapsed. The maximum range of the timer is 99 hours, 59 minutes, and 59 seconds. After the maximum range is reached, the timer displays all zeros (00:00:00). Park Assist Menu The park assist menu is displayed in the DIC. The DIC displays the current state of the park assist until the IPC receives a message indicating otherwise. The DIC displays (- - -) when communication with park assist is lost. English/Metric The English/Metric mode is used to toggle between English and Metric units and can be accessed through the driver information center (DIC) Vehicle Info switch. Trip A/B The trip odometer A or B can be accessed through the DIC Trip/Fuel switch function. Language The driver information center (DIC) is capable of displaying in 8 languages * English * German * Italian * French * Spanish * Arabic * Chinese * Korean Page 15832 9. Position the oil pan skid plate and install the bolts, if equipped. Tighten the bolts to 28 N.m (21 lb ft). 10. Lower the vehicle. 11. Connect the negative battery cable. Page 10784 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Rear Side Access Door Trim Panel Replacement Rear Door Panel: Service and Repair Rear Side Access Door Trim Panel Replacement Rear Side Access Door Trim Panel Replacement Page 7993 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 7004 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 21943 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 17068 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 10295 Fuel: Service Precautions Gasoline/Gasoline Vapors Caution Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Page 19246 For vehicles repaired under warranty, use the table above. Disclaimer Page 17290 X115 Inline Harness Connector End Views X115 Chassis Harness to Instrument Panel Harness (JL4) Page 20084 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 5125 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 5855 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Electrical - No Start/No Crank/Int Electrical Operations Wiring Harness: All Technical Service Bulletins Electrical - No Start/No Crank/Int Electrical Operations TECHNICAL Bulletin No.: 08-06-03-007 Date: June 27, 2008 Subject: No Start, No Crank, Intermittent Electrical Operations (Check For Poor Connections Within Engine Wiring Harness Junction Block) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment on a no start, or no crank, or intermittent electrical operations. Cause This may be caused by probing fuse or relay connectors with incorrect J-Tools, which causes splayed terminals and poor electrical connections. Customers may also have installed wires adjacent to the fuse connector blades in order to create an electrical circuit, which also creates a potential loose connection at the fuse. Other potential causes are probing by independent repair shops during installation of aftermarket accessories like remote start systems. Correction If the terminals are damaged beyond repair, the engine wiring harness junction block will have to be replaced. Be sure to use the correct J-Tool (J-356616-35), which is designed to prevent splaying of the terminals and loose connections. Important: DO NOT use any other device (incorrect J- Tool, multi-meter probe) to test fuse/relay terminals. The figure shown shows splayed fuse terminals due to probing with a round instrument, which caused a poor electrical connection between fuse blade and terminal (note lack of witness mark on fuse blade). The figure above shows a wire jammed into fuse slot (potential electrical tap by customer). Warranty Information This repair will not be covered under warranty due to damage/failure caused by inappropriate probing or customer abuse. Page 7015 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 4648 Oil Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. If equipped, remove the oil pan skid plate bolts and plate. 3. Remove the drain plug and drain the oil into a suitable container. 4. Remove the oil filter. Page 1568 Wheel Speed Sensor: Service and Repair Front Wheel Speed Sensor Replacement (JH6, JH7) Front Wheel Speed Sensor Replacement (JH6, JH7) Page 24577 Page 15826 Starter Motor: Service and Repair Starter Motor Replacement (4.3L) Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the negative battery cable. 2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the oil pan skid plate bolts and plate, if equipped. 4. Remove the starter solenoid cable clip bolt (2) from the frame. Page 13563 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 21589 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 5391 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 9249 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Controls Component Viewst Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Page 12063 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 21610 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 23078 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 3081 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 16208 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 631 Page 11168 View of the connector when released from the component. View of another type of Micro 64 connector. Page 5311 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 14113 Parts Information Warranty Information For transmission electrical repairs please note in the technicians comments field on the repair order which terminal number(s) were repaired or replaced. Also if a male terminal is bent (transmission side of connector), then indicate the bent terminal number on the repair order. For vehicles repaired under warranty, use the table above. Disclaimer Page 23578 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Page 9768 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 8613 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 23476 For vehicles repaired under warranty, use the table. Disclaimer Page 17008 Fuse: Application and ID Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 1135 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 6017 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Page 15419 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement (JH6, JH7) Brake Pressure Modulator Valve Replacement (JH6, JH7) Page 16251 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 20920 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverage Adjustments are displayed in the Applicable Warranties section. Parts Information Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Replace door handle levers if signs of peeling are present. Note The handle kit contains two door handle levers, replace both sides. Front Side Door Inside Handle Replacement 1. Remove the driver and passenger front side door inside handles. Refer to Front Side Door Inside Handle Replacement in SI. 2. Place front door inside handles on a work bench. Page 3107 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Body - Outside Door Handle Pulls Out of Base Rear Door Exterior Handle: All Technical Service Bulletins Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information Page 12340 5. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 6. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 7. Remove the TCC solenoid bolts. 8. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 9. Reposition the harness to the side of the transmission case. 10. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 11. Remove the transmission fluid pressure switch. Page 15463 1. Connect the left park brake cable (2) to the intermediate park brake cable connector (1). 2. Connect the front park brake cable (2) to the intermediate park brake cable connector (1). 3. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling. 4. Adjust the park brake. Refer to Park Brake Adjustment (Disc Brake) Park Brake Adjustment (Drum Brake). Parking Brake Rear Cable Replacement - Left Side (JD9) Parking Brake Rear Cable Replacement - Left Side (JD9) Removal Procedure Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: Customer Interest Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 21054 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Extended Cab, Power) Rear Side Door Window Regulator Replacement (Extended Cab, Power) Page 15879 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 19118 Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Crew Cab +ASF) Page 1841 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 16430 X309 Inline Harness Connector End Views X309 Body Harness to Console Harness (Y91) Page 22057 Page 1569 Page 13161 9. Remove the transmission heat shield. 10. Lower the transmission slightly. 11. Disconnect the transmission oil cooler lines. 12. Plug the transmission oil cooler line fittings. 13. Remove the indicator tube nut. Page 9164 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 14809 2-3 Shift Solenoid (SS) Valve, Wiring Harness Side 3-2 Shift Solenoid (SS) Valve Assembly, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Page 6178 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 11366 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 1116 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 6920 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 12033 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (367A) and the 1-2 shift solenoid retainer (395). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. 4. Install the pressure control solenoid (377). Notice: Refer to Fastener Notice. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Page 1026 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 18348 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 4104 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 9305 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 6176 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 7599 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 12818 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 5174 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 6765 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21839 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 14322 Parts Information Warranty Information For IP clusters replaced/programmed due to customer satisfaction concerns of poor backlighting, the warranty claim MUST be submitted using the labor operation listed in this bulletin. Disclaimer Page 9808 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: * The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. * Apply the park brake. * The engine must start in the park (P) or neutral (N) positions only. * Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 9214 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 16926 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 23548 Page 6086 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5456 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 6722 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 11254 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Hood Front Seal Replacement Hood Weatherstrip: Service and Repair Hood Front Seal Replacement Hood Front Seal Replacement Page 22697 Note Ensure that the cross-car adhesive foam is positioned at a height just below the insulator push pin fastener locations so that once the fasteners are installed, the seal is compressed. - Across the inner rear body panel, matching the width of the insulator panel. - Downward from each end of the cross-car foam (left side (1) shown in the graphic above). The length should match the height of the insulator panel. - Partially around the two PRV's. Install the foam down the outboard side (1), underneath (2), partially back up the inboard side (3), then finish with a length extending further inboard (4) from the PRV. Important Ensure that any C-pillar wiring harnesses/connectors are routed forward of the insulator, and not trapped behind it. 4. Position the body rear panel insulator to the inner rear body panel and install the push pin retainers. Caution should be taken to not disturb the foam tape installed previously. Page 5906 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch Page 13939 Transmission Speed Sensor: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Input and Output Speed Sensor (ISS/OSS) Page 13673 Shift Cable: Adjustments 4L60-E/4L65-E/4L70-E - Automatic Transmission Range Selector Lever Cable Adjustment 1. Ensure that the steering column shift lever is in the park (P) position. 2. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Ensure that the transmission manual shaft lever is in the park (P) position. 4. Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand. 5. Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1). 6. Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together. Pressure Regulator Replacement Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 14908 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 6113 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 21793 Page 22869 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the rear door sill plate. Refer to Rear Side Door Sill Plate Replacement (Extended Cab) Rear Side Door Sill Plate Replacement (Crew Cab) . 4L60-E/4L65-E/4L70-E Transmission Mount Inspection Transmission Mount: Testing and Inspection 4L60-E/4L65-E/4L70-E Transmission Mount Inspection Transmission Mount Inspection Notice: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the rubber. 2. Observe the transmission/transaxle mount while raising the transmission/transaxle. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: Important: Black paint on the rubber will crack with time, this does no constitute a failure. * The hard rubber surface is covered with heat check cracks. * The rubber is separated from the metal plate of the transmission/transaxle mount. * The rubber is split through the center of the transmission/transaxle mount. 3. If there is movement between the metal plate of the transmission/transaxle mount and its attaching points, lower the transmission/transaxle on the transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount to the frame or transmission/transaxle mount bracket. Page 9050 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 6511 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 22696 color of the rear inner panel (shown circled above) below the insulator (1), the insulator is the original design, which is trimmed straight across the bottom. Order a service body rear panel insulator (pictured above), referencing the parts table below. Note that the new insulator has an increased thickness and the height was extended on both ends. R & R the rear seat and any necessary trim to replace the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Further Repair for Customer Enthusiasm Only in situations when the above repairs are completed and the customer is still commenting on objectionable noise, the following additional steps can be done to sound-proof the body rear panel. This additional sound-proofing should only be done in cases deemed necessary for customer enthusiasm. Note After this procedure has been performed, the vehicle needs to be re-assembled and evaluated with the trim and rear seat fully installed in the vehicle. If the bulletin has been followed properly, the noise should be reduced to a level quieter than stock 2011 models, and no further repairs should be attempted. It has been found that controlling the wind noise at the two pressure relief valve (PRV) locations is the key to quieting the rear cab wind noise. The repair below has been found to be successful in eliminating most of the objectionable noise. 1. R & R the rear seat and any necessary trim to remove the body rear panel insulator. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. Note GM P/N 12378195 is not available in Canada. However several equivalents such as *Evercoat (Q-Pads) P/N 100116 and *Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. 2. Install noise and vibration sound deadening pads to backside of the body rear panel insulator. Follow the pattern shown above, ensuring they cover the two PRV locations. Use GM P/N 12378195, or equivalents commercially available through *Dynamat(R), Evercoat(R) or Dominion Sure Seal. Important Ensure that the foam tape pattern does not have any gaps in the corners and that it is securely pressed/attached to the inner rear body panel. 3. Install *Duck Brand Weatherstrip Seal (Self Adhesive Foam) P/N 1278750, or equivalent, to the inner body rear end panel following the patterns shown below: Page 14686 Tighten the bolt to 11 N.m (97 lb in). 6. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 7. Install the 1-2 accumulator, if necessary. 8. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 9. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 17882 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Page 4759 15. Install the engine shield and bolts. Tighten the bolts to 20 N.m (15 lb ft). 16. Install the oil pan. 17. Install the crankshaft balancer. 18. Install the water pump. Page 6508 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 18379 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 23153 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 21520 Rear Window Lower Garnish Molding Replacement (Ext Cab/Crew Cab w/o A48) Restraints - Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 16762 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Adjustments Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment 1. Open the sunshade. 2. Close the sunroof window. 3. Loosen the adjusting screws on each side of the sunroof window. * Crew Cab has two screws. * Extended Cab has three screws. 4. Adjust the corners of the window panel using the following guidelines: * Adjust the front of the sunroof window flush to 2 mm (0.08 in) below the top surface of the roof panel. * Adjust the rear of the sunroof window flush to 2 mm (0.08 in) above the top surface of the roof panel. Notice: Refer to Fastener Notice. 5. Install the sunroof window adjustment screws. Tighten the screws to 4 N.m (35 lb in). * Crew Cab has two screws. * Extended Cab has three screws. Page 23930 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 23404 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the negative battery cable. 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 21852 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 12694 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 18612 Ambient Temperature Sensor / Switch HVAC: Diagrams HVAC Connector End Views Ambient Air Temperature Sensor - HVAC Page 21844 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Heater Control Module: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 18010 Tire Pressure Module: Service and Repair Control Module Setup Remote Control Door Lock Receiver (RCDLR) Setup After remote control door lock receiver assembly replacement, the following procedures must be performed in the order that they appear for the tire pressure monitor (TPM) System to function properly. The RCDLR also requires keyless entry transmitter programming after replacement. Refer to Transmitter Programming. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool select Vehicle Control System. 4. Select Module Setups. 5. Select Remote Control Door Lock Receiver. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle drivers door placard sticker. 9. Select the rear tire pressure as noted on the vehicle drivers door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After RCDLR assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the RCDLR memory. Refer to Tire Pressure Sensor Learn. Page 22268 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 11391 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 23022 - + RES switch - Cancel switch * Rotate the steering wheel to both steering stops and activate each cruise control switch separately. With a scan tool, observe the Cruise On/Off Switch, Cruise Resume/Accel Switch, Cruise Set/Coast Switch and Cruise Cancel Switch parameters in the ECM Cruise Control data list. This will help eliminate the possibility of an internally shorted inflatable restraint steering wheel module coil. * Inspect for proper operation of the stop lamps and the braking system. * Electromagnetic interference (EMI) on the speed sensor signal circuit may cause erratic cruise control operation. Circuit/System Verification Important: Repair any brake system related symptoms and DTCs before performing this diagnostic. Ignition ON, cruise on/off switch ON, rotate the steering wheel to both steering stops while activating each cruise control switch separately. With a scan tool, observe all cruise control switch parameters in the BCM. Verify that each cruise control switch activated and that each displayed switch position parameters match accordingly with each depressed switch, as the steering wheel is turned. Circuit/System Testing 1. Ignition OFF, remove the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement. 2. Disconnect the harness connector of the steering wheel control switch assembly - left. 3. Ignition ON, measure for 10 volts or greater between the 12-volt reference circuit terminal 1 and ground. ‹› If less than 10 volts, test the 12-volt reference circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the BCM. 4. Ignition OFF, disconnect the harness connector X1 of the BCM. 5. Ignition OFF, test for 1.0 ohm of resistance or less between the steering wheel control switch assembly - left terminal 3 and the BCM X1 terminal 3. ‹› If greater than the specified range, test the cruise control switch signal circuit for an open/high resistance. 6. Ignition OFF, test for infinite resistance between the BCM X1 terminal 3 and ground. ‹› If less than the specified value, test the cruise control switch signal circuit for a short to ground. 7. Ignition ON, test for 0 volts between the BCM X1 terminal 3 and ground. ‹› If greater than the specified value, test the cruise control switch signal circuit for a short to voltage. 8. Test the component. If all circuits and the component tests are normal, replace the BCM. Component Testing Important: The cruise control ON/OFF switch must be ON in order to properly measure the resistance of the - SET, the + RES, and the Cancel switches. 1. With the ignition OFF, remove the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement. 2. With the ignition OFF, disconnect the harness connector at the steering wheel control switch assembly - left. 3. Measure the resistance between terminals 1 and 3 at the cruise control switch side of the connector. Individually activate and hold each cruise control function switch and compare the resistance reading to the values on the schematic for the ON/OFF, - SET, the + RES, and the Cancel switches. ‹› If any of the resistance measurements for the OFF, ON, - SET, + RES, and Cancel switches are not within the listed resistance values, replace the cruise control switch assembly. Repair Instructions Page 17655 Notice: Refer to Fastener Notice. Important: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3). Tighten the TORX screw to 1.3 N.m (11.5 lb in). Important: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 1. Apply tire soap to the rubber portion of the valve stem (1). 2. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 2310 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. Notice: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 2. Remove the MAP sensor bolt (1). 3. Using a slight rocking motion while pulling straight up, remove the MAP sensor (2) from the upper intake manifold. 4. Inspect the MAP sensor seal for damage, replace the seal if necessary. Installation Procedure Page 8905 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11327 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 3734 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement (Non-HP2) Page 23568 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 6301 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 18201 Air Door Actuator / Motor: Diagrams HVAC - Manual HVAC Connector End Views Air Temperature Actuator Mode Actuator Page 9099 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 12775 Pressure Regulating Solenoid: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control (PC) Solenoid Valve, Wiring Harness Side Page 5925 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 17714 Notice: Refer to Power Steering Hose Disconnected Notice. 2. Disconnect the power steering fluid cooler hose clamp and hose (3) from the steering gear (2). 3. Remove the power steering gear outlet pipe (1) from the steering gear (2). Installation Procedure 1. Install the power steering gear outlet pipe (1) to the steering gear (2). 2. Connect the power steering fluid cooler hose (3) and hose clamp to the steering gear (2). 3. Clean any excess fluid from the vehicle and remove the drain pans. 4. Fill and bleed the power steering system. Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas Without Hydroboost) Page 14974 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 3917 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 17079 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 5546 Tighten the right exhaust manifold pipe bolts in the sequence indicated in illustration "B" above. Tighten: Tighten the bolts to 50 N.m (37 lb ft). Tighten the Y-pipe outlet to the exhaust muffler assembly. Tighten: Tighten to 45 N.m (33 lb ft). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 9670 Page 5460 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 10653 21. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 N.m (18 lb ft). 22. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. 23. Lower the vehicle. 24. Remove the caps from the fuel rail and EVAP line. 25. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. 26. Connect the fuel feed line (1) quick connect fitting to the fuel rail. 27. Install the fuel fill cap. 28. Connect the negative battery cable. 29. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Allison - Automatic Transmission Transmission Speed Sensor: Service and Repair Allison - Automatic Transmission Speed Sensor Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Page 23141 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 12405 Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Notice: Refer to Fastener Notice. 3. Install the speed sensor bolt (1). Tighten bolt to 12 N.m (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Page 16759 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Electronic Brake Control Module Replacement (JD9, JF3, JF7) Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement (JD9, JF3, JF7) Electronic Brake Control Module Replacement (JD9, JF3, JF7) Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant System Capacities Page 12094 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 22480 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 10851 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 6768 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 6994 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 11491 8. Remove the engine wiring harness rear bracket bolts and bracket. Important: Note the routing of the spark plug wires prior to disconnecting the wires from the ignition coil. 9. Disconnect the spark plug wires (1, 2) from the ignition coil. 10. Reposition the spark plug wires out of the way. Page 23122 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Diagrams Oil Pressure Sender: Diagrams Displays and Gages Connector End Views Engine Oil Pressure (EOP) Sensor (Gas) Page 22289 Disclaimer Page 19534 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 9172 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 3333 21. Remove the spacer plate support bolts (77). 22. Remove the spacer plate support (53). 23. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). Notice: Refer to Fastener Notice. 2. Install the spacer plate support (53) and bolts (77). Tighten the bolts to 10 N.m (89 lb in). Page 14772 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Campaign - HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 18431 Control Module HVAC: Diagrams HVAC Connector End Views Blower Motor Control Module X1 Blower Motor Control Module X2 Page 13591 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 9424 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 1290 Page 22146 Power Seat Motor: Service and Repair Front Seat Lumbar Support Replacement Front Seat Lumbar Support Replacement The front seat lumbar support is serviced as part of the seat back assembly. If the lumbar support needs to be replaced the entire seat back frame kit will need to be installed. Refer to Front Seat Back Frame Replacement. Page 12280 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 20525 Auxiliary Body Control Module (XBCM) X2 (Export) Page 9303 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 22407 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 22350 Page 24244 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 12904 Shift Solenoid: Connector Views 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views 1-2 Shift Solenoid (SS) Valve, Wiring Harness Side Page 7928 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 3860 Fuse: Locations Right I/P Junction Block Junction Block - Right I/P, Top View Locations Power Window Switch: Locations Window Systems Component Views Passenger Door 1 - Outside Rearview Mirror - Passenger 2 - Door Lock Switch - Passenger (AU3 -AN3/DL3) 3 Passenger Door Switch (PDS) (AN3/DL3) 4 - Door Latch Assembly - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) 6 - Speaker - Right Front 7 - Window Motor - Passenger (A31) 8 - Window Switch - Passenger (A31 -AN3/DL3) 9 - Heated Seat Switch Passenger (AN3) Left Rear Door (Crew Cab) Page 1687 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Page 12018 4. Install the pressure control solenoid (377). 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Tighten the bolt to 11 N.m (97 lb in). 6. Install the TCC PWM solenoid to the control valve body. 7. Install the TCC PWM solenoid retainer. 8. Connect the internal wiring harness electrical connectors to the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * TCC PWM solenoid (5) * 3-2 control solenoid (6) 9. Install the 1-2 accumulator. 10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. 11. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), Page 15462 1. Release the park brake. 2. Disable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Disabling. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 4. Disconnect the front park brake cable (2) from the intermediate cable connector (1) by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector. 5. Disconnect the left park brake cable (2) from the intermediate cable connector (1) by drilling a 3 mm (1/8 in) hole through the dimple in the front to intermediate park brake cable connector. 6. Remove the intermediate park brake cable. Installation Procedure Interior - Poor Carpet/Rubber Mat Fit/Loose/Bulging Sound Proofing / Insulation: All Technical Service Bulletins Interior - Poor Carpet/Rubber Mat Fit/Loose/Bulging Bulletin No.: 07-08-110-007B Date: November 30, 2007 TECHNICAL Subject: Front Floor Carpet or Rubber Floor Covering Poor Fit, Loose or Bulging (Install Floor Insulator/Deadener) Models: 2007-2008 Chevrolet Silverado Regular Cab 2007-2008 GMC Sierra Regular Cab with Carpet (RPO B30) or Rubber (RPO BG9) Floor Covering Supercede: This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin Number 07-08-110-007A (Section 08 - Body and Accessories). Condition Some customers may comment on the way the front floor carpet or rubber floor covering (1) fits on the center of the floor tunnel. Others may comment that the floor covering is loose, bulging or just fits poorly on the passenger side. Cause This condition may be caused by a lack of padding under the front floor carpet or rubber floor covering. Correction Install floor insulator/deadener to the top of the floor tunnel using the steps below. For vehicles equipped with a manual 4 x 4 shifter, the shifter knob and trim plate will need to be removed. Refer to Transfer Case Control Lever Replacement in SI. Remove the carpet or rubber floor covering away from the front floor tunnel. Refer to Floor Panel Carpet Replacement (Regular Cab) in SI. Tip The instrument panel (IP) support bracket will need to be removed by prying apart the two trim panels and removing the bolts. Page 21539 Page 7279 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 11044 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 7124 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 545 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 5342 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Service and Repair Horn Switch: Service and Repair Horn Switch Replacement Page 16408 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) (U42) Page 11195 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 562 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 21620 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 21435 Instrument Panel Compartment Door Latch Replacement (without RPO SLT) Instrument Panel Compartment Door Latch Replacement (without RPO SLT) Page 17952 Please note the following when referring to a specific illustration: ^ When using the illustrations for back to back comparisons of two hubs, the most obvious differences are visible on the back side of the hubs. ^ The most common area of physical difference are in the shape of the four mounting bosses and their surrounds. Disclaimer Page 3357 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 8192 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 13464 Transmission Mode Switch: Locations Shift Lock Control Component Views Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7) Engine Oil Cooler Pipe/Hose Quick Connect Fitting Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Engine Oil Cooler Pipe/Hose Quick Connect Fitting Removal Procedure 1. Disengage the plastic caps from the quick connect fittings. Pull the caps back along the pipe. 2. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 3. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. Discard the retaining rings. 4. Remove the engine oil cooler line from the quick connector fitting at the radiator. Pull the lines straight out from the connectors. 5. Clean all of the components in a suitable solvent, and dry them with compressed air. 6. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure Important: When performing the following procedure, do not reuse the old retaining rings. Replace the old retaining rings with new ones. Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. 1. Install a new retaining ring into each quick connector fitting. Page 17359 X211 Inline Harness Connector End Views X211 Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) to Console Harness (Y91/UQA/D07) Page 9918 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 17115 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 22334 Front Seat Cushion Inner Trim Panel Replacement Front Seat Cushion Inner Trim Panel Replacement Page 9505 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 23231 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 10640 Brakes - Aftermarket Trailer Brake Controllers Trailer Brake Control Module: All Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 17787 9. Remove the 2 pivot pins (3) from the steering column tilt head assembly (1) by using remover J 21854-01 (2). 10. Install the tilt lever into the steering column tilt head assembly (1). 11. Pull back on the tilt lever and at the same time, pull the steering column tilt head assembly (1) down and away from the steering column. 12. Remove the steering column tilt head assembly. 13. Remove anti-rotation pin J 42640. 14. Remove the tilt lever. 15. Remove the steering shaft upper bearing from the steering column tilt head assembly. Page 479 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 14791 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 6627 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 12587 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 1758 Important: Use a NEW steering shaft lock plate retaining ring. 1. Install the following parts onto the steering shaft: 1. Lubricate the turn signal switch cancel cam (3) with GM P/N 12377900 (Canadian P/N 10953529). 2. Turn signal switch cancel cam position plate (2) 3. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137. 2. Install the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Page 23054 Page 6939 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 22943 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 9182 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 11680 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Allison - Automatic Transmission Transmission Speed Sensor: Service and Repair Allison - Automatic Transmission Speed Sensor Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure Page 23950 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 7887 Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CMP sensor, install a NEW O-ring seal onto the sensor. 2. Install the CMP sensor to the wiring harness jumper. 3. Connect the CMP sensor wiring harness jumper to the CMP sensor. 4. Lubricate the O-ring seal with clean engine oil. 5. Install the CMP sensor and wiring harness jumper to the engine front cover. Notice: Refer to Fastener Notice. 6. Install the CMP sensor bolt. Tighten the bolt to 10 N.m (89 lb in). 7. Install the water pump. 8. Connect the engine wiring harness electrical connector (7) to the CMP sensor wiring harness jumper. Page 3670 Fluid Filter - A/T: Service and Repair Allison - Automatic Transmission Transmission Fluid Filter Adapter Replacement Transmission Fluid Filter Adapter Replacement Removal Procedure Important: * DO NOT drain the fluid if only the transmission external oil filter adapter is being replaced. * Use a standard strap-type filter wrench to remove or install the transmission external oil filter. Remove the transmission external oil filter (4) by rotating in the counterclockwise direction. 1. Remove the magnet (2) from the transmission external oil filter adapter (1) in the converter housing or from the filter element. 2. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. 3. Remove the filter adapter (1) from the converter housing. Installation Procedure 1. Install the transmission external oil filter adapter (1). Notice: Refer to Fastener Notice. Tighten the adapter to 30 N.m (22 lb ft). 2. Reinstall the magnet (2) onto the filter adapter (1). 3. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 4. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 5. Turn the filter ONE FULL TURN ONLY after gasket contact. Notice: Use only clean and approved transmission fluid. 6. Check the transmission fluid level. Page 7869 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 16266 Junction Block - Left I/P, Bottom View Page 11970 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 996 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 15473 5. Release the right park brake cable from the frame bracket by compressing the locking tabs and pulling the cable conduit (3) rearward. 6. Release the park brake cable (1) from the rear axle housing cover clip. 7. Remove the park brake cable clip bolt (2). 8. Release the park brake cable from the rear axle bracket by compressing the locking tabs and pulling the park brake cable conduit (1) rearward. 9. Disconnect the park brake cable eye (2) from the park brake actuator lever. 10. Remove the park brake cable assembly from the vehicle. Installation Procedure Page 17006 Page 9988 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 10809 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 6926 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 9696 Page 4059 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 22669 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (Crew Cab) Removal Procedure 1. Remove the overhead console in order to access the sunroof switch. 2. Disconnect the electrical connector from the sunroof switch. 3. With a flat-bladed tool, carefully release the tabs that retain the sunroof switch to the overhead console. 4. Remove the sunroof switch from the overhead console. Installation Procedure 1. Position the sunroof switch alignment tabs to the slots in the console. 2. Install the sunroof switch into the console, ensuring that the retaining tabs are fully seated. 3. Connect the electrical connector to the sunroof switch. 4. Install the overhead console to the roof. Page 4932 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 13600 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 1259 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 21438 Instrument Panel Compartment Door Opening Frame Replacement (Without RPO SLT) Instrument Panel Compartment Door Opening Frame Replacement (Without RPO SLT) Page 9435 Page 7645 Page 1024 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 9382 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 15134 Electronic Brake Control Module (JF3/JF7) Page 6540 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 409 Trailer Brake Control Module: Service and Repair Trailer Brake Control Relay Replacement Trailer Brake Control Relay Replacement Page 12661 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Diagrams Headlamp Switch: Diagrams Lighting Systems Connector End Views Headlamp and Panel Dimmer Switch Page 17910 Locations Wheel Speed Sensor: Locations Antilock Brake System Component Views Front Sensors 1 - Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7/JH6/JH7) 2 - Chassis 3 - Wheel Speed Sensor (WSS) - Left Front (JL4/JF3/JF7/JH6/JH7) Rear Sensors Page 2612 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 23421 Tire Pressure Module: Service and Repair Control Module Setup Remote Control Door Lock Receiver (RCDLR) Setup After remote control door lock receiver assembly replacement, the following procedures must be performed in the order that they appear for the tire pressure monitor (TPM) System to function properly. The RCDLR also requires keyless entry transmitter programming after replacement. Refer to Transmitter Programming. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool select Vehicle Control System. 4. Select Module Setups. 5. Select Remote Control Door Lock Receiver. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle drivers door placard sticker. 9. Select the rear tire pressure as noted on the vehicle drivers door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After RCDLR assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the RCDLR memory. Refer to Tire Pressure Sensor Learn. Page 9704 Throttle Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 10863 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 2470 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 15399 Rear Brake Hose Replacement (Caliper - JH6, JH7) Rear Brake Hose Replacement (Caliper - JH6, JH7) Locations Brake Fluid Level Sensor/Switch: Locations Antilock Brake System Component Views Left Side of the Engine Compartment 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (- MYC) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Page 8102 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Wiring Harness: All Technical Service Bulletins Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Page 11708 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 6607 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 9344 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 18806 Disclaimer Page 13033 Torque Converter Clutch Solenoid: Connector Views 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Internal Connector End Views Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side Page 9646 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 9625 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 23370 Page 6085 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 18637 Low Pressure Sensor / Switch: Locations HVAC - Manual HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 2016 Page 6359 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 6446 Page 615 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 21640 Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 9642 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 9186 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 9307 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 7891 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Controls Component Viewst Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Page 22481 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 2765 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 19571 analyzed. Therefore, technicians should be checking for loose connections and installing cable connector clamps to ensure a positive and robust connection. Technicians are to install a video cable connector clamp on each cable connector located under each front seat. A total of four cable connector clamps, P/N 19159659, are required for each vehicle. The illustration above shows a pair of display monitor cable connectors without the cable clamps installed. The illustration above shows the display monitor cable connectors with the cable connector clamps. The lower cable connector clamp is installed but not locked together. The upper cable connector clamp is closed and locked. The cable connector clamps have now been added as a permanent component to all GM Accessories Headrest DVD Systems installation kits. Parts Information Warranty Information (excluding Saab U.S. Models) Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 21379 Front Floor Panel Carpet Replacement (Extended Cab) Front Floor Panel Carpet Replacement (Extended Cab) Page 9521 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 22595 Passenger Door Switch (PDS) X4 (AN3) Page 9381 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 11546 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 2352 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 2914 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 13607 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 15902 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14403 Drive/Propeller Shaft: Service and Repair Propeller Shaft Boot Replacement Propeller Shaft Boot Replacement Page 8289 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 2768 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 14671 powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 12. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 7393 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 16735 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 13578 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2240 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 11773 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 11514 Page 2079 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 4518 7. Position the engine wiring harness and bracket. 8. Connect the ECT sensor electrical connector (5). 9. Install the engine wiring harness clip bolt (4). Tighten the bolt to 9 N.m (80 lb in). 10. Install the engine wiring harness bracket. 11. Install the engine wiring harness bracket nuts. Tighten the nuts to 12 N.m (106 lb in). Trim Height Inspection Alignment: Service and Repair Trim Height Inspection Trim Height Inspection Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can the vehicle to cause bottom out over bumps, damage to the suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label. * Check the fuel level. Add additional weight if necessary to simulate a full tank of gas. (One U.S. gallon of gasoline weights approximate 6.5 lbs. One liter of gasoline weights 0.70 kg) * Make sure the passenger and rear compartments are empty, except for the spare tire. * Make sure the vehicle is on a level surface, such as an alignment rack. * For vehicles equipped with automatic level control, make sure that the system is functioning properly. * Make sure that all doors, lift gate/trunk and the hood are securely closed. * Check for installed after market accessories or modifications that could affect trim height measurements: - Larger or smaller than production wheels and tires - Lifting or lowering kits - Wheel opening flares - Ground affects * Remove the alignment rack floating pins. Measuring the Z Height Important: For vehicles equipped with torsion bars, the Z height must be verified before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use a adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. Important: All dimensions are measured vertical to ground. Cross vehicle Z heights should be within 12 mm (0.47 in) to be considered correct. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. Page 2775 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 6039 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 16267 Junction Block - Left I/P X1 Page 11127 Page 6254 Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CMP sensor, install a NEW O-ring seal onto the sensor. 2. Install the CMP sensor to the wiring harness jumper. 3. Connect the CMP sensor wiring harness jumper to the CMP sensor. 4. Lubricate the O-ring seal with clean engine oil. 5. Install the CMP sensor and wiring harness jumper to the engine front cover. Notice: Refer to Fastener Notice. 6. Install the CMP sensor bolt. Tighten the bolt to 10 N.m (89 lb in). 7. Install the water pump. 8. Connect the engine wiring harness electrical connector (7) to the CMP sensor wiring harness jumper. Page 4184 procedure. What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Recycle it by taking it to a place that collects used oil. Brake Fluid Effects on Paint and Electrical Components Notice Paint: Service Precautions Brake Fluid Effects on Paint and Electrical Components Notice Brake Fluid Effects on Paint and Electrical Components Notice Notice: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid. Drivetrain - Gen II Vs. Gen III Wheel Hub Changes Wheel Hub (Locking): Technical Service Bulletins Drivetrain - Gen II Vs. Gen III Wheel Hub Changes INFORMATION Bulletin No.: 08-03-08-003A Date: March 02, 2009 Subject: Wheel Hub Changes - Gen III vs. Gen II Models: 2008 and Prior Cadillac Escalade Models 2008 and Prior Chevrolet Avalanche, Silverado, Silverado Classic, Suburban, Tahoe 2008 and Prior GMC Sierra, Sierra Classic, Yukon Models Supercede: This bulletin is being revised to update the parts information in the table and to add an Illustrated Hub Gallery depicting all wheel hub part numbers called out below for visual identification purposes. Please discard Corporate Bulletin Number 08-03-08-003 (Section 03 - Suspension). General Motors Vehicle Engineering has introduced a new design Gen III front wheel hub for the above listed vehicles that replaces the Gen II product. These Gen II 4x2 and 4x4 applications that were previously serviced by seven part numbers are now serviced by three Gen III part numbers. Concerns have been expressed by technicians regarding the use of the new supersessions and whether the Gen III hubs will properly fit the vehicles being serviced, especially because of visual and functional differences (splines). This bulletin has been developed to address those concerns. Please refer to the table above for information on the Gen III replacement part for each Gen II application. At the end of the bulletin you will find an illustrated "Hub Gallery" with graphic depictions of both Gen II and replacement style Gen III parts. Using these illustrations you should be able to identify both the Gen II and Gen III wheel hubs. Warning If replacing wheel studs, please refer to the GM Parts Catalog for the correct stud part number for each application. Different types of studs are used depending on the wheel hub application. When replacing an older Gen II design 4x2 hub with a new 4x2/4x4 common Gen III hub, it is acceptable to have a bearing with splines on it for a 4x2 application that previously did not. However, the older Gen II design 4x4 hubs should NOT be used on a 4x2 vehicle. The Gen II 4x4 hub relies on the tension of the wheel drive shaft joint to hold everything together. The roll form feature on the inboard side of the new 4x2/4x4 Gen III hub eliminates this concern. The only hub that is not back serviceable is P/N 15719007 (not pictured) for 1999-2000 C25 applications due to a different hub flange to bearing flange offset. Important: Only the new part numbers referenced in this bulletin are interchangeable between the 4x2 and 4x4 applications with the exception of P/N 15719007 (Not Shown). Under no circumstances should any other 4x4 hub be used in a 4x2 application. Illustrated Hub Gallery Page 13730 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Page 11201 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 22465 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 8070 Page 14616 Transmission Position Switch/Sensor: Service and Repair Allison - Automatic Transmission Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 13034 Torque Converter Clutch (TCC) Solenoid Valve, Wiring Harness Side Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Pressure Control Solenoid 1 (PCS1) Torque Converter Clutch Pressure Control Solenoid (TCC PCS) Page 6855 Page 23246 2. Install the fuse(s) supplying power to the SDM. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle Exhaust System - Moan/Vibration Noise At Low RPM Exhaust Pipe/Muffler Hanger: All Technical Service Bulletins Exhaust System - Moan/Vibration Noise At Low RPM TECHNICAL Bulletin No.: 02-06-05-003J Date: February 16, 2011 Subject: Exhaust Moan/Vibration Noise (Install Exhaust System Flex Pipe Kit) Models: 1999-2007 Chevrolet Silverado 1500 Series Extended Cab or Regular Cab/Long or Short Box Pickups (Classic) 2007-2011 Chevrolet Silverado 1500 Series Extended Cab or Regular Cab/Long or Short/Standard Box Pickups (New Body Style) 1999-2007 GMC Sierra 1500 Series Extended Cab or Regular Cab/Long or Short Box Pickups (Classic) 2007-2011 GMC Sierra 1500 Series Extended Cab or Regular Cab/Long or Short/Standard Box Pickups (New Body Style) Equipped with 4.3L Engine (VINs W, X - RPOs L35, LU3) and Automatic Transmission (RPO M30) New Body Style 2007-2011 Fort Wayne (VIN Z - RPO FWI) Built Vehicles Before January 2011 and All Silao (VIN G - RPO MSL) Built Vehicles Supercede: This bulletin is being revised to add the 2011 model year and vehicle build information. Please discard Corporate Bulletin Number 02-06-05-003I (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a moan or vibration noise at low vehicle speeds 40-64 km (25-40 mph) or between 900-1700 RPM under load. Cause Exhaust system resonance may be transmitted through the powertrain mounts into the body causing this condition. Correction Caution Personal injury or burns may occur when working on a hot exhaust system, let the exhaust system cool off prior to performing the repair. An exhaust system flex pipe kit is available to correct this condition. If diagnosis leads to this condition, install the applicable exhaust system flex pipe kit listed below using the following procedure. Refer to the Parts Information for kit applications and usage. Important This fix and the kit part numbers are specific to vehicle frame type. A Level 3 frame was introduced interim 2000 model year (approximately January 2000). With a Level 3 frame, the transmission crossmember was moved forward of its previous location. Pre-Level 3 frames will require the installation of additional components to correct the condition. 1999-2000 4WD Models Built Prior to 1/20/2000 and All 2000-2011 2WD and 4WD Models Built After 1/2000 (Fort Wayne Built Vehicles Before 1/2011 and All Silao Built Vehicles) (Except Regular Cab Short Bed Vehicles) These models require the installation of a flex coupling. The flex coupling has adapter sleeves for the installation of U-bolt clamps. This procedure uses the U-bolt clamps, but the preferred installation method is to weld the flex coupler to the exhaust pipe. 1. Raise the vehicle. 2. Locate the first available straight section of pipe rearward of the mid-joint flange and forward of the muffler assembly. 3. Measure approximately 228 mm (9 in) on the straight pipe and mark. 4. Using a suitable cutting tool, cut out the marked section of the pipe and remove. 5. Remove any burrs, if necessary, before installing the flex coupler pipe. Page 1126 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 11036 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 12044 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Disable the SIR system. 2. Remove the knee bolster. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Temperature Versus Resistance Page 24650 Page 3135 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 11221 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 8164 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 18702 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or the Investigate Vehicle History screen (dealers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information No parts are required for this program. Service Procedure 1. If the vehicle is equipped with vinyl flooring and no cutout flap under the driver's seat, no further action is required. For all other vehicles, proceed to Step 2. Note Driver seat removal is NOT required for crew cab or extended cab vehicles. Certain 2009 regular cab vehicles built after approximately March 1, 2009 with carpet that has a 2-sided cutout over the SDM, however, will require driver seat removal. Refer to Front Seat Replacement-Bucket in SI. After the seat removal, proceed to Step 2 in the bulletin. Regular cab vehicles with carpet that has a 3-sided cut over the SDM do NOT require seat removal. Page 18704 2. Courtesy Transportation - For dealers using WINS, submit using normal labor code; for dealers using GWM - submit as Net Item under the repair labor code. Customer Notification General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter October 2009 Dear General Motors Customer: We have learned that your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra, currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. Your vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Your satisfaction with your 2007, 2008, or 2009 model year Chevrolet Silverado or GMC Sierra is very important to us, so we are announcing a program to prevent this condition. What We Will Do: Your GM dealer will remove the acoustical padding above the SDM. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. Page 23440 Notice: Refer to Fastener Notice. Important: * Ensure the flat of the valve, lines up with the flats of the snap in the enclosure. * TPM valves and TORX screws are one-time use only. Assemble the tire pressure sensor (2) to the valve stem and install the new TORX screw (3). Tighten the TORX screw to 1.3 N.m (11.5 lb in). Important: Use and approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A corrosive type compound can cause tire or rim deterioration. 1. Apply tire soap to the rubber portion of the valve stem (1). 2. Using a tire valve stem mounting tool, pull the valve stem through in a direction parallel to the valve hole on the rim. Page 19985 Audio Amplifier X3 (UQA) Page 14875 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 9911 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 14836 Page 2145 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 22951 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 3162 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Engine Controls - Cruise Control Turns Off When Operated Engine Control Module: All Technical Service Bulletins Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 24684 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 9585 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 22993 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 4631 * Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. * Do not use the plastic cap in order to install the cooler line into the fitting. If equipped with RPO L76 (6.0L) engine, perform the following: 1. Install the oil cooler hoses to the hose clip on the fan shroud. 2. Snap the oil cooler hose clip shut. 15. Install the oil cooler lines to the radiator. Specifications Compression Check: Specifications No cylinder should read less than .............................................................................................................................................................. 690 kpa (100 psi) Page 9087 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 6333 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 12855 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8260 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. OnStar(R) - Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 13733 Caution: Avoid personal injury or property damage when removing or installing the torque converter by seeking an assistant to help lift the torque converter. 3. Lift the torque converter into the transmission. 4. Spin the torque converter to engage the turbine shaft splines in the torque converter hub, the stator shaft splines in the stator race and to engage the drive flats on the converter pump hub with the oil pump drive gear. 5. The torque converter is correctly installed when the distance from the lugs to the mounting face is the same as when measured before removing the torque converter. 6. Install J 21366. 7. Reinstall the transmission into the vehicle. Important: The FastLearn (adapt) procedure must be performed. This can be done in one step using a scan tool. If this procedure is not done, the TCM's adaptive values will be at the settings that it learned for the old components. and will be in slow adaptive mode. Under these conditions, it would take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 8. Perform the FastLearn procedure. Page 6332 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 7441 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Circuit/System Verification Important: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. Ignition ON, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. ‹› If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 1. Ignition OFF, all accessories OFF, install the CH-48027. Refer to Fuel Pressure Gage Installation and Removal. See: Fuel Pressure Gage Installation and Removal 2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Important: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Restricted or plugged fuel filter * Restricted or plugged strainer * Stuck or binding fuel level float * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel Page 10660 13. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 N.m (18 lb ft). 14. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. 15. Lower the vehicle. 16. Remove the caps from the fuel rail and EVAP line. 17. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. 18. Connect the fuel feed line (1) quick connect fitting to the fuel rail. 19. Install the fuel fill cap. 20. Connect the negative battery cable. 21. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Page 15751 5. Remove the auxiliary battery positive cable nut (1) from the mega fuse holder. 6. Remove the generator battery jumper cable to fuse nut (3). 7. Remove the generator battery jumper cable terminal (2) from the fuse stud. 8. Remove the auxiliary battery positive cable from the fuse studs. 9. Remove the upper mega fuse nut (1), if necessary. 10. Remove the appropriate mega fuse (2). Installation Procedure Page 1145 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 8318 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 12674 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Garage Door Opener Description and Operation (One LED) Garage Door Opener Transmitter: Description and Operation Garage Door Opener Description and Operation (One LED) Garage Door Opener Description and Operation (One LED) The garage door opener (GDO) is located in the overhead console or drivers side sunshade. If battery voltage is lost due to a condition such as a dead battery, the GDO unit relies on the non-serviceable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for the garage doors, electric entrance gates, or lighting and security systems. The GDO is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the GDO to change every time the GDO is used within operating range of the receiver. Rolling code programming requires the customer to push a learn/program button on the GDO receiver at their home. This button is usually located on the receiver unit under a cover (light cover) on one end of the unit. The customer must follow the GDO manufacturers instructions to program/learn the receiver to accept the Universal Home Remote System as an authorized opener for their unit. When the receiver and the GDO are initially programmed together, a code is established and a new code is created for every new transmission. The software in the receiver recognizes the GDO and accepts the new code. The GDO is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, refer to 1-800-355-3515. The GDO is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters. Refer to Programming and Relearning for setup and programming. See: Testing and Inspection/Programming and Relearning The GDO has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 GDOs, security gates, and lighting systems. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Page 14190 Pinion Gear: Service and Repair Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Drive Pinion and Ring Gear Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Tools Required * J 22536 Pinion Driver, 8.6 inch, 9.5/9.5LD inch axles * J 44421 Pinion Remover, 11.5 inch axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion yoke and the oil seal. 4. Install the J 22536, 8.6 inch or 9.5/9.5LD inch axle, or the J 44421, 11.5 inch axle as shown. Ensure that the J 22536 or the J 44421 is firmly seated on the pinion. 5. Drive the pinion out using the J 22536 or the J 44421 and a hammer. Strike the J 22536 or the J 44421 slowly. Do not let the pinion fall out of the rear axle housing. 6. Remove the collapsible spacer from the pinion. Discard the spacer. 7. Remove the pinion bearings and the cups. Important: The ring gear bolts on the 8.6 inch and the 9.5/9.5LF inch axles have left-hand threads. The ring gear bolts on the 11.5 inch axle have right-hand threads. 8. Remove the gear bolts. Discard the bolts. Notice: Refer to Ring Gear Removal Notice. 9. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. Page 4456 4. Install the balance shaft driven gear. 5. If reusing the fastener, apply threadlocker to the threads of the balance shaft driven gear bolt. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 6. Install the balance shaft driven gear bolt. 1. Use a wrench to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 2. Install the balance shaft driven gear bolt. 1. Tighten the bolt a first pass to 20 N.m (15 lb ft). 2. Tighten the bolt a final pass an additional 35 degrees using J 45059. 7. Remove the wrench from the balance shaft. 8. Rotate the balance shaft by hand in order to ensure that there is clearance between the balance shaft and the valve lifter pushrod guide. If the balance shaft does not rotate freely, check to ensure that the retaining ring on the balance shaft front bearing is seated on the case. 9. Install the balance shaft drive gear. DO NOT install the camshaft sprocket bolts at this time. 10. Rotate the camshaft so that the timing mark on the balance shaft drive gear is in the 12 o'clock position. Page 14887 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 11296 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 16276 Junction Block - Left I/P X9 Page 9414 Fuel Tank Pressure Sensor: Diagrams Engine Controls Connector End Views Fuel Tank Pressure (FTP) Sensor Page 11597 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: All Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 22397 1 - Heated Seat Element - Passenger Back 2 - Heated Seat Element - Passenger Cushion Service and Repair Steering Shaft Coupler: Service and Repair Steering Shaft Coupling Replacement Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Caution: Refer to Restraint System Service Precautions. Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly. 1. Set the front wheels in the straight-ahead position. 2. Install anti-rotation pin J 42640 in the steering column lower access hole. 3. Remove the engine shield. 4. Mark the relationships of the steering shaft coupling, the upper intermediate steering shaft, and the power steering gear. 1. Mark the relationship of the upper intermediate steering shaft to the steering shaft coupling. 2. Mark the relationship of the steering shaft coupling to the steering gear. Important: DO NOT pull on the steering shaft coupling to separate it from the steering gear. 5. Remove the steering shaft coupling bolt at the steering gear. Page 19276 Keyless Entry Receiver: Service and Repair Remote Control Door Lock Receiver Replacement Page 231 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7831 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 13451 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 6293 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 11274 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 11539 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 10716 Fuel Filler Hose: Service and Repair Filler Tube Replacement (Regular Cab w/34 Gal Tank) Filler Tube Replacement (Regular Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe screws. 3. Remove the fuel tank filler housing. 4. Partially raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and the chassis harness ground wire (1), if equipped. Service and Repair Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Page 3949 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved A/C - HVAC Control Module Lockup During Reprogramming Control Module HVAC: All Technical Service Bulletins A/C - HVAC Control Module Lockup During Reprogramming Bulletin No.: 06-01-39-014 Date: December 06, 2006 INFORMATION Subject: Information On HVAC Control Module Lockup During Reprogramming Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) The purpose of this bulletin is to alert technicians to a condition they may encounter while trying to reprogram a Heating, Ventilation and Air Conditioning (HVAC) control module. If the HVAC control module reprogramming event is interrupted, the control module may go into a "lock up" mode. This will cause the HVAC control module to disable communications and a second try at reprogramming will fail. The interruption may be caused by a software anomaly inside the HVAC control module. If the HVAC reprogramming event was interrupted and a subsequent reprogramming attempt fails, perform a battery reset. This can be accomplished by either removing and reinstalling the HVAC BATT fuse, located in the underhood fuse block, or by disconnecting and reconnecting the HVAC control module connector C2. Connector C2 is grey in color with 16 cavities. Once the battery reset has been performed, the HVAC control module will resume communications and will then be able to be reprogrammed. The Warranty Parts Center (WPC) has received HVAC control modules that have been returned and described as non-functional but were tested with no problems found. If the module has been replaced due to a failed second attempt at reprogramming caused by the lock up, the module will be returned and charged back to the dealer. Technicians must also remember that after a new HVAC control module has been installed into a vehicle, it must be programmed, otherwise it will not be functional. Disclaimer Page 6217 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 16334 For vehicles repaired under warranty, use the table. Disclaimer Page 5845 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 14841 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 10268 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 14796 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 5061 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 15757 5. Install the starter solenoid cable terminal (2) to the fuse stud. 6. Install the starter solenoid cable nut (1) to the fuse stud. Tighten the nut to 9 N.m (80 lb in). 7. Install the fuse cover. 8. Connect the negative battery cable. Page 19120 A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Page 24157 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 21718 Memory Seat Module X5 (AN3) Page 13210 Fluid Filter - A/T: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement Page 8892 Page 21841 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 4622 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting until a click is heard or felt. Pull back on the engine oil cooler lines to ensure a proper connection. Page 23602 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 7287 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 4461 2. Remove the J 38834. 3. Install the balance shaft. Page 19815 Page 12981 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 15685 Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Page 4971 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 7123 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 23860 Page 11303 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6529 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 15898 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 10967 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 21587 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 17125 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 7428 Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (2) up and over the knock sensor. Page 10236 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Campaign - HVAC Blower Not Functional Runs Continuously Blower Motor Resistor: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Interior - Slit/Cut in Front Carpet/Rubber Covering Carpet: All Technical Service Bulletins Interior - Slit/Cut in Front Carpet/Rubber Covering Bulletin No.: 08-08-110-002 Date: February 11, 2008 INFORMATION Subject: Information on Slit or Cut in Front Floor Carpet or Rubber Floor Covering Under Drivers Seat Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2008 GMC Sierra (New Body Style), Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Carpet (RPO B30) or Rubber (RPO BG9) Floor Covering Some customers may comment on a slit or cut in the front floor carpet or rubber floor covering under the drivers seat. This slit is an access cut for servicing the inflatable restraint sensing and diagnostic module (SDM). The slit (1) is more noticeable when the seat track assembly is in the full rear position. DO NOT replace the front floor carpet or rubber floor covering. A service replacement carpet or mat will contain the same slit. Please inform your customer that the slit in the carpet or rubber floor covering is normal and provides service access to the inflatable restraint sensing and diagnostic module (SDM) (1). Page 4377 Wheel Hub: Specifications Hub Nut ............................................................................................................................................... .................................................... 240 N.m (177 lb ft) Page 24535 Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link. Not all vehicles within Page 2139 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 3922 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 17764 Important: Discard the steering linkage shock absorber nut. 4. Remove the steering linkage shock absorber bolt (2) and nut (3). 5. Remove the steering linkage shock absorber (1) from the vehicle. 6. Inspect the following parts: * The steering linkage shock absorber for leaks and damage * The steering linkage shock absorber bolt for damage or corrosion Installation Procedure Important: Use new steering linkage shock absorber nuts. 1. Install the steering linkage shock absorber (2) to the vehicle. 2. Install the steering linkage shock absorber (4) and nuts (1, 3). Notice: Refer to Fastener Notice. Page 18647 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 7834 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 2590 Installation Procedure 1. Position the accelerator pedal to the accelerator pedal bracket. Notice: Refer to Fastener Notice. 2. Install the accelerator pedal bolts. Tighten the bolts to 9 N.m (80 lb in). 3. Connect the APP sensor electrical connector (1). 4. Connect a scan tool to the diagnostic port in order to test for proper throttle-opening and throttle-closing range. 5. Operate the accelerator pedal and monitor the throttle angles. The accelerator pedal should operate freely, without binding, between a closed throttle, and a wide open throttle (WOT). 6. Verify that the vehicle meets the following conditions: Page 13226 4. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 5. Install the cooler line into the quick connect fitting. 6. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 7. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 8. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 9. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 10. Ensure that the plastic cap is fully seated against the fitting. Page 10946 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 10682 17. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 18. Install the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 19. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 20. Install the fuel line clip (1) to the bracket on the automatic transmission. Page 8292 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 5347 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 1655 Page 12504 Shift Interlock Solenoid: Diagrams Shift Lock Control Connector End Views A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid A/T Shift Lock Control Solenoid Page 14227 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a NEW pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. Notice: Refer to Fastener Notice. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 7. Tighten the pinion nut while holding the J 8614-01. Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3-5 lb in) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts. Tighten the bolts to 25 N.m (18 lb ft). Page 8370 Information Bus: Testing and Inspection Scan Tool Does Not Communicate with High Speed GMLAN Device Scan Tool Does Not Communicate with High Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description Modules connected to the high speed GMLAN serial data circuits monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules when the ignition switch is in any position other than OFF. The high speed GMLAN serial data circuits must be operational for the vehicle to start due to body control module (BCM) and engine control module (ECM)/powertrain control module (PCM) communications. The theft deterrent module and ECM/PCM exchange information using the BCM as the gateway module allowing communication between the high and low speed serial data busses. The low speed GMLAN serial data circuit must also be operational for vehicle starting. Diagnostic Aids * Use the Data Link References to identify the high speed GMLAN serial data modules. * This test is used for a total high speed GMLAN communication failure. If only one module is not communicating and sets no DTC, ensure that the vehicle is equipped with the module, then use DTC U0100-U0299 for diagnostics. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate to set up the vehicle on the tool and then not communicate with the vehicle. When the scan tool is to the point of communicating with the vehicle, a message on the scan tool will indicate "no CANdi module detected" and will not communicate. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. The following conditions may cause a total loss of high speed GMLAN data communication: - A short between high speed GMLAN (+) and high speed GMLAN (-) circuits - Any of the high speed GMLAN serial data circuits shorted to ground or voltage - A module internal malfunction that causes a short to voltage or ground on the high speed GMLAN circuits * Use the DMM MIN/MAX function to capture/locate intermittent conditions. Circuit/System Testing 1. Test for less than 1 ohm of resistance between the DLC ground circuit terminal 5 and ground. ‹› If greater than 1 ohm, test the ground circuit for open/high resistance. 2. Ignition OFF, disconnect the harness connector of the BCM. 3. Ignition ON, test for battery voltage between each voltage input circuit of the BCM and ground. ‹› If less than battery voltage, test each voltage output circuit of the BCM for a short to ground, and each voltage input circuit of the BCM for a short to ground or and open/high resistance. If the circuits test normal, replace the faulty module. 4. Test for less than 1 ohm of resistance between each ground circuit of the BCM and ground. Page 11145 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 5919 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 5517 1. If replacing the catalytic converter assembly, perform the following steps, otherwise proceed to step 4. 2. If reinstalling the old sensors, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Component Fastener Tightening Notice. 3. Install the HO2S (1-4) to the catalytic converter assembly. Notice: Refer to Fastener Notice. Tighten the sensors to 42 N.m (31 lb ft). 4. Install the NEW exhaust seals (2 and 3) as required. 5. Install the catalytic converter assembly to the muffler. 6. Install the catalytic converter assembly to the exhaust manifolds. 7. Install the catalytic converter to exhaust manifold nuts (1). Tighten the nuts to 50 N.m (37 lb ft). Page 13759 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Service and Repair Oil Change Reminder Lamp: Service and Repair Engine Oil Life System When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it indicates that an oil change is necessary. A CHANGE ENGINE OIL SOON message comes on. See DIC Warnings and Messages. Change the oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if driving under the best conditions, the oil life system might not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. Your dealer/retailer has trained service people who will perform this work using genuine parts and reset the system. It is also important to check the oil regularly and keep it at the proper level. If the system is ever reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change. Remember to reset the oil life system whenever the oil is changed. How to Reset the Engine Oil Life System (From Owner's Manual) The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Whenever the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message coming on, reset the system. Always reset the engine oil life to 100% after every oil change. It will not reset itself. To reset the Engine Oil Life System: 1. Display the OIL LIFE REMAINING on the DIC. If the vehicle does not have DIC buttons, the vehicle must be in P (Park) to access this display. 2. Press and hold the SET/RESET button on the DIC, or the trip odometer reset stem if the vehicle does not have DIC buttons, for more than five seconds. The oil life will change to 100%. If the CHANGE ENGINE OIL SOON message comes back on when the vehicle is started, the Engine Oil Life System has not reset. Repeat the procedure. GM Oil Life System Resetting (From Service Manual) When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL SOON message will come on. Change the engine oil as soon as possible within the next 1 000 km (600 miles). It is possible that, if driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, change the engine oil at 5 000 km (3,000 miles) since last oil change. How to Reset the Engine Oil Life System (From Service Manual) The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Anytime the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message being turned on, reset the system. If the vehicle does not have a Driver Information Center (DIC), do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Fully press and release the accelerator pedal slowly three times within five seconds. 3. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the procedure. If the vehicle has a DIC, do the following: 1. Turn the ignition to ON, with the engine OFF. 2. Press the MODE button until the DIC reads OIL LIFE LEFT/HOLD SET TO RESET. 3. Press and hold the SET button until 100 percent is displayed. You will hear three chimes and the CHANGE ENGINE OIL SOON message will go off. 4. Turn the key to OFF. If the CHANGE ENGINE OIL SOON message comes back on when you start the vehicle, the engine oil life system has not reset. Repeat the Page 15435 Page 24559 Service Procedure Important The windshield solvent heater module (1) is located on the driver's side of the engine compartment near the front fender upper brace (if equipped), master cylinder reservoir, and lower plenum panel. For the Cadillac DTS and Buick Lucerne, the windshield solvent heater module is mounted to the front of dash on the passenger's side of the engine compartment. 1. Locate the windshield solvent heater module. 2. Disconnect the windshield solvent heater module wire harness (1) from the heater module (2). 3. Connect the jumper harness with the in-line fuse (1) to the windshield solvent heater module wire harness (2) as shown in the illustration. Page 9124 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 13429 Fluid Pressure Sensor/Switch: Diagrams Automatic Transmission Internal Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Page 21861 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 16505 Power Distribution Relay: Service and Repair Relay Replacement (Within an Electrical Center) Relay Replacement (Within an Electrical Center) Tools Required J 43244 Relay Puller Pliers Removal Procedure 1. Remove the electrical center cover. 2. Locate the relay. Important: * Always note the orientation of the relay. * Ensure that the electrical center is secure, as not to put added stress on the wires or terminals. Using the J 43244 (1) position the tool on opposing corners of the relay (2). Notice: Use J43244 to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center. 4. Remove the relay (2) from the electrical center. Installation Procedure Page 7950 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 21145 For vehicles repaired under warranty, use the table. Disclaimer Page 21012 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 7882 Page 17705 Important: The power steering gear inlet hose cannot be routed between the brake lines and the power brake booster during installation. 1. Route the power steering gear inlet hose in the same position it was in prior to removal. 2. Install the power steering gear inlet hose (2) to the power brake booster (1) and hand tighten only. Rotate the power steering gear inlet hose clockwise until the it contacts the power brake booster housing and then hold it in position while tightening it to the fitting specification. Notice: Refer to Fastener Notice. 3. Install the power steering gear inlet hose (2) to the power steering gear. Tighten the fittings to 32 N.m (24 lb ft). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Page 6068 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 6120 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 8871 For vehicles repaired under warranty, use the table. Disclaimer Page 12496 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 14092 Parts Information Warranty Information For transmission electrical repairs please note in the technicians comments field on the repair order which terminal number(s) were repaired or replaced. Also if a male terminal is bent (transmission side of connector), then indicate the bent terminal number on the repair order. For vehicles repaired under warranty, use the table above. Disclaimer Page 10795 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 955 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 8071 Page 20724 YE7 Front Side Door Trim Panel Replacement (YE9) Page 10815 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 12117 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 6044 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 2774 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9361 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 8113 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 3307 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 10993 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 601 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 9641 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 7039 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 9608 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 9687 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the connector position assurance (CPA) retainer. 3. Disconnect the HO2S pigtail electrical connector (5) from the engine wiring harness electrical connector (4). 4. Remove the HO2S (2). Installation Procedure Page 18357 Control Assembly: Service and Repair HVAC - Manual HVAC Control Module Replacement Page 4990 Page 12864 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 8581 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7968 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 6247 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 8161 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Tow Hook Replacement (1500/2500 Series) Towing Hook / Bracket: Service and Repair Tow Hook Replacement (1500/2500 Series) Tow Hook Replacement (1500/2500 Series) Page 9301 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 2465 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 8282 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Service and Repair Front Door Hinge: Service and Repair Front Side Door Hinge Replacement Page 12535 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 22717 Page 6535 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 4050 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 22341 Page 1374 Passenger Door Switch (PDS) X1 (AN3/DL3) Passenger Door Switch (PDS) X2 (AN3/DL3) Page 23043 Visually inspect and pull on the C2 Audio Amplifier Connector (1). If the connector is properly seated, then refer to SI for further diagnosis based on the customers condition. If the connector is loose, then reinstall the C2 Audio Amplifier Connector. Verify the connector is seated and locked into place. Install the fuses. Verify the condition has been fixed and clear any DTCs. If securing the connector does not correct the condition, refer to SI for further diagnosis and repair. Install the radio speaker amplifier assembly and any other components removed to gain access to the amplifier. Refer to Radio Speaker Amplifier Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10816 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 6049 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 7838 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6524 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2989 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 4896 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 4144 Junction Block - Rear Lamps X2 Page 1961 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 8218 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 12248 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Torque Converter: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 9517 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 1115 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 20390 5. Install the retainers (1) securing the trailer wiring harness (2) to the hitch platform. 6. Connect the trailer wiring harness connector (3) to the trailer wiring recepticle (4). Page 21878 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Locations Cabin Temperature Sensor / Switch: Locations HVAC Component Views Front Headliner Components 1 - Inside Air Temperature Sensor - Front (CJ2) 2 - Cellular Microphone (UE1/U3U/UVB) 3 Courtesy/Reading Lamps - Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade - Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly 8 - Inside Rearview Mirror (ISRVM) 9 - Courtesy/Reading Lamps - Front 10 - Windshield 11 - Sunshade - Left (DH6) Page 11965 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Specifications Information Bus: Specifications Fastener Tightening Specifications Page 7108 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11492 11. Disconnect engine wiring harness electrical connector (7) from the ignition coil. 12. Reposition the engine wiring harness branches out of the way as required. 13. Remove the ignition coil bolts and coil from the bracket. Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor. 4. Use the J 43631 to press the stud from the wheel bearing/hub. Installation Procedure 1. Install a new stud. Use washers and a wheel nut and pull the new stud into the hub. 2. Install the brake rotor. 3. Install the tire and wheel. 4. Lower the vehicle. Locations Driver/Vehicle Information Display: Locations Displays and Gages Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 4758 Important: When installing the CKP sensor, make sure the sensor is fully seated before tightening the bolt. A poorly seated sensor may perform erratically and may set false DTCs. 12. Install the CKP sensor and bolt. Tighten the bolt to 8 N.m (71 lb in). 13. Connect the CKP sensor electrical connector (2). 14. Install the engine wire harness clip (1) to front cover. Page 4457 11. Remove the balance shaft drive gear. 12. Rotate the balance shaft so that the timing mark on the balance shaft driven gear is in the 6 o'clock position. 13. Position the balance shaft drive gear onto the engine camshaft. 14. Look to ensure that the balance shaft drive gear and the balance shaft driven gear timing marks are aligned. 15. Install the timing chain and the camshaft sprocket. 16. Install the valve lifter pushrod guide. 17. Install the A/C condenser. 18. Install the radiator. Page 17021 Fuse Block: Locations Entertainment/Communication Component Views Entertainment/Communication Component Views Behind the I/P 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 +YE9) 6 - Digital Radio Receiver (U2K) Page 21828 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 11576 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14186 23. Remove the inner pinion bearing cup using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. Installation Procedure 1. Install the inner pinion bearing cup into the pinion gear bearing retainer using the J 37624 (2) and the J 8092 (1). 2. Install the outer pinion bearing cup into the pinion gear bearing retainer using the J 8608 (2) and the J 8092 (1). 3. Install the inner pinion bearing using the J 24433. Press the bearing on until the cone seats on the pinion. 4. Install a new collapsible spacer. 5. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Page 1930 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 7765 Body Control Module (BCM) X6 Page 2087 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 1534 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement (With RPO JL1 and Without JL4) A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Valve Body: All Technical Service Bulletins A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 5301 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 16790 Auxiliary Power Outlet: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Tools Required J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure Page 17352 X202 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Page 3952 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Dipstick - Dipstick Tube: Service and Repair 4L60-E/4L65-E/4L70-E Automatic Transmission Transmission Fluid Filler Tube and Seal Replacement Removal Procedure 1. Remove the intake manifold. 2. Unlock the transmission oil level indicator. 3. Remove the transmission oil level indicator. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Support the transmission using a suitable jack. 6. Remove the transmission crossmember. 7. Loosen the left exhaust pipe nuts. 8. Loosen the right exhaust pipe nuts. Page 2903 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 19053 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 18446 Air Temperature Sensor - Lower Right Page 21598 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9341 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8776 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer A/T Controls - DTC P1825/P182E or P1915/MIL ON Transmission Mode Switch: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 11663 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11106 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 21400 Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Front Floor Console Side Trim Panel Replacement - Right Side (with RPO SLT) Page 9328 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 8365 Information Bus: Vehicle Damage Warnings Data Communication Schematic Icons Page 23279 Page 14272 1. Position the boot (1) so that it is seated properly in the groove (2) in the wheel drive shaft (3). 2. Install the small boot clamp (2) on the boot (1). 3. Using the J 35910 , a breaker bar, and a torque wrench (1), close the boot clamp (2) until the gap (3) measures 2.15 mm (0.085 inch). Page 10384 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 12787 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Actuator Replacement Removal Procedure 1. Disable the SIR system. 2. Remove the knee bolster. 3. Put the shift lever clevis into the neutral position. 4. Disconnect the electrical connector. 5. Using a small screwdriver, pry the automatic transmission shift lock control actuator away from the steering column jacket and the cable shift cam. 6. Remove the shift lock control actuator. Installation Procedure 1. Firmly install the shift lock control actuator onto the steering column jacket and the cable shift cam. Page 17118 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 1359 Hood Sensor/Switch (For Alarm): Diagrams Immobilizer Connector End Views Hood Ajar Switch (AP3/AP8) Page 10847 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 12482 10. Using J 28458, release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. 12. Inspect the TCC solenoid and wiring harness for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Page 20002 Warranty Information (Saab U.S. Models) Disclaimer 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Specifications 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Shift Solenoid Valve State and Gear Ratio Page 17122 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 16403 X202 Inline Harness Connector End Views X202 Instrument Panel Harness to Body Harness Page 17495 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 2665 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 19533 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Heater Core Cover Replacement Heater Core: Service and Repair Heater Core Cover Replacement Heater Core Cover Replacement Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. Remove the tire from the wheel. Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 3. Remove the tire pressure sensor nut. 4. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Locations Horn Relay: Locations Horn Relay The Horn PCB Relay is located in the Fuse Block - Underhood. Note: This relay is a Printed Circuit Board (PCB) Relay, and is not serviceable. Page 11928 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 10865 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 5897 Page 11706 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 12532 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 3144 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 4891 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 9732 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 4128 Junction Block - Left I/P X5 (SPO Alarm) Junction Block - Left I/P X7 (JF4) OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 9857 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 8100 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 9970 Catalytic Converter: Service Precautions Three-Way Catalytic Converter Damage Notice Notice: In order to avoid damaging the replacement three-way catalytic converter, correct the engine misfire or mechanical fault before replacing the three-way catalytic converter. Page 4851 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Page 9220 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 4227 Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE MONITOR SYSTEM The Tire Pressure Monitor System (TPMS) uses radio and sensor technology to check tire pressure levels. If your vehicle has this feature, sensors are mounted on each tire and wheel assembly, except the spare tire. The TPMS sensors monitor the air pressure in your vehicle's tires and transmit tire pressure readings to a receiver located in the vehicle. The TPMS is designed to alert the driver, if a low tire pressure condition exists. If your vehicle has the Driver Information Center (DIC), the driver may also check tire pressure levels using the DIC. When a low tire pressure condition is detected, the TPMS will illuminate the low tire pressure warning symbol located on the instrument panel cluster. If your vehicle has the DIC feature, a message to check the pressure in a specific tire will also appear on the DIC display. The low tire pressure warning symbol on the instrument panel cluster and the "CHECK TIRE PRESSURE" warning message on the DIC display will appear at each ignition cycle until the tires are inflated to the correct inflation pressure. You may notice, during cooler weather conditions, that the tire pressure monitor light, located on the instrument panel cluster, and the "CHECK TIRE PRESSURE" message will appear when the vehicle is first started and then turn off as you start to drive the vehicle. This could be an early indicator that the tire pressures are getting low and need to be inflated to the proper pressure. Each tire, including the spare (if provided), should be checked monthly when cold and inflated to the inflation pressure recommended by the vehicle manufacturer on the vehicle placard or tire inflation pressure label. (If your vehicle has tires of a different size than the size indicated on the vehicle placard or tire inflation pressure label, you should determine the proper tire inflation pressure for those tires.) As an added safety feature, your vehicle has been equipped with a tire pressure monitoring system (TPMS) that illuminates a low tire pressure telltale when one or more of your tires is significantly under-inflated. Accordingly, when the low tire pressure telltale illuminates, you should stop and check your tires as soon as possible, and inflate them to the proper pressure. Driving on a significantly under-inflated tire causes the tire to overheat and can lead to tire failure. Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle's handling and stopping ability. Please note that the TPMS is not a substitute for proper tire maintenance, and it is the driver's responsibility to maintain correct tire pressure, even if under-inflation has not reached the level to trigger illumination of the TPMS low tire pressure telltale. Your vehicle has also been equipped with a TPMS malfunction indicator to indicate when the system is not operating properly. The TPMS malfunction indicator is combined with the low tire pressure telltale. When the system detects a malfunction, the telltale will flash for approximately one minute and then remain continuously illuminated. This sequence will continue upon subsequent vehicle start-ups as long as the malfunction exists. When the malfunction indicator is illuminated, the system may not be able to detect or signal low tire pressure as intended. TPMS malfunctions may occur for a variety of reasons, including the installation of replacement or alternate tires or wheels on the vehicle that prevent the TPMS from functioning properly. Always check the TPMS malfunction telltale after replacing one or more tires or wheels on your vehicle to ensure that the replacement or alternate tires and wheels allow the TPMS to continue to function properly. The "CHECK TIRE PRESSURE" warning message and low tire pressure light (telltale) will come on each time the vehicle is started until the tires are inflated to the correct inflation pressure. The Tire and Loading Information label (tire information placard) shows the size of your vehicle's original tires and the correct inflation pressure for your vehicle's tires when they are cold. Your vehicle's TPMS can alert you about a low tire pressure condition but it does not replace normal tire maintenance. NOTICE: Do not use a tire sealant if your vehicle has Tire Pressure Monitors. The liquid sealant can damage the tire pressure monitor sensors. Page 3077 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 7602 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 6394 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 13264 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten the bolts in the sequence shown to 11 N.m (97 lb in). 15. Ensure that the manual detent spring is aligned properly with the detent lever. Page 17902 Remove the front suspension strut mount (1), front spring upper seat (2), front suspension strut bumper (3), front spring upper insulator (4), and the front suspension spring (5) from the spring compressor. Installation Procedure Install the front spring lower insulator (1) on the shock absorber (2). Assembly the front suspension strut mount (1), front spring upper seat (2), front suspension strut bumper (3), and the front spring (5). Page 21580 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 8986 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 7909 Page 10271 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 12348 20. Install the TCC PWM solenoid (1) to the valve body. 21. Install the TCC PWM solenoid retainer (2). 22. Connect the internal wiring harness electrical connectors to the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) 23. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 24. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 14907 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Procedures Steering Angle Sensor: Procedures Steering Wheel Position Sensor Centering Removal Procedure Important: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 1. Verify the type of steering wheel position sensor. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on the right. Important: If reusing the existing sensor, you do not have to align the sensor before removal. Centering is not required when it is time to reinstall. 3. Remove the connector from the sensor. 4. Remove the sensor (1) from the adapter and bearing assembly. 5. To install the sensor, proceed to step 1 in the installation section. 6. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for centering the pin-Note the location of the pin hole. * A flush rotor flange cuff (4) Important: If reusing the existing sensor, you must make an alignment mark on the rotor flange cuff (3) before removing the sensor. Failure to do so will cause misalignment when installing the sensor. A new sensor will be required if misaligned. 7. Make an alignment mark on the flush rotor flange cuff (3). 8. Remove the connector from the sensor. 9. Remove the sensor from the adapter and bearing assembly. 10. To install the sensor, proceed to step 5 in the installation procedure. Page 18663 Solar Sensor: Service and Repair Sun Load Sensor Replacement Page 5903 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 15893 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 6882 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 5293 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 19012 Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: All Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 13674 Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 7. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 15635 Trailer Brake Control Module: Diagrams Trailer Brake Controller Module (TBCM) Electronic Suspension Control (ESC) Module Page 2219 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Body - Outside Door Handle(s) Squeak When Operated Rear Door Exterior Handle: All Technical Service Bulletins Body - Outside Door Handle(s) Squeak When Operated TECHNICAL Bulletin No.: 08-08-64-007 Date: May 13, 2008 Subject: Squeaky Outside Door Handle (Grease U-Channel of Handle) Models: 2007-2008 Cadillac Escalade, Escalade EXT, Escalade ESV 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Condition Some customers may comment on a squeak noise coming from the door handle as the handle is actuated. Cause This condition may be caused by the pin and the inside of pawl surface making contact with each other, resulting in a squeak noise. Correction DO NOT REPLACE THE DOOR HANDLE. 1. Remove the fasteners to the door handle, leaving the rod to the latch attached. 2. Apply a generous amount of dielectric silicone grease, P/N 12345579 (in Canada, 10953481), as shown in the graphics, into the U-channel of the handle between the pawl and the tower where the gray pin enters through the spring and the pawl. 3. Cycle the handle at least 20 times to work the grease around the pin and to make sure that the squeak has been eliminated. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 958 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 4954 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 16920 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Heater Inlet Hose Replacement (Non-HP2) Heater Hose: Service and Repair Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose Replacement (Non-HP2) Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. 6. Remove the inlet heater hose from the water pump. 7. Remove the inlet heater hose. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components Refer to SIR Identification Views. There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Caution: When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose inflator modules to temperatures above 65°C (150°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 91 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any Inflatable restraint air bag module * Inflatable restraint steering wheel module coil * Any Inflatable restraint sensor * Inflatable restraint seat belt pretensioners * Inflatable restraint Passenger Presence System (PPS) module or sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Important: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. 4. Wait 1 minute before working on the system. Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. Page 10965 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 6688 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice Heated Oxygen Sensor Resistance Learn Reset Notice Notice: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 1914 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10504 Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end. 2. Push both sides of the fuel line connections together in order to snap the retaining tabs into place. 3. Once installed, pull on both sides of the fuel line connections to ensure that the connection is secure. Page 17087 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 7298 Crankshaft Position Sensor: Connector Views Engine Controls Connector End Views Crankshaft Position (CKP) Sensor Page 22924 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 23092 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 1732 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement (without RPO SLT) Fog Lamp Switch Replacement (without RPO SLT) Page 2496 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Stop Lamp Switch Brake Light Switch: Diagrams Stop Lamp Switch Lighting Systems Connector End Views Stop Lamp Switch Body - Squeak/Itching Noise in Upper Door Area Front Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 964 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 745 Brake Lamp Relay: Locations TRLR LT STOP/TURN PCB Relay Electrical Center Identification Views Fuse Block - Underhood, Label A/C - Control Module A/C Indicator Blinking Control Module HVAC: All Technical Service Bulletins A/C - Control Module A/C Indicator Blinking Bulletin No.: 07-01-38-006 Date: August 20, 2007 INFORMATION Subject: Information For Vehicles with HVAC Control Module A/C Indicator Blinking Due to Low Battery State of Charge Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Manual Temperature Control HVAC System (RPO CJ3) An Air Condition (A/C) button on the Heating, Ventilation and Air Conditioning (HVAC) control module may blink when the A/C system is activated. The blinking indicator will turn to a solid light after cycling the A/C button or ignition key. This condition may be caused by a low battery state of charge on a PREVIOUS ignition key cycle. This condition may be due to situations were an unsold vehicle is parked for long periods of time as part of a dealership's unsold inventory. The A/C indicator begins to flash if the battery voltage falls below 9.5 volts. The low voltage condition may occur during an engine crank or if the vehicle is parked and a normal battery state of charge is not maintained. If the A/C indicator continues to blink, use the Tech 2(R) to help determine the cause. Connect the Tech 2 and build the vehicle. Select Powertrain. Select Engine Control Module (ECM). Select Data Display. Select Cooling/HVAC data. Make sure that there has been an A/C request signal. History should indicate any causes. If necessary, refer to SI for further information on HVAC system diagnostic procedures. Page 12938 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 5792 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 6169 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 10840 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 8593 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 22597 Page 290 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Page 10242 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 6530 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 3156 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 4149 Page 16890 Page 10956 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 593 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 13007 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 8263 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 6418 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 3956 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 3093 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 12497 Pressure Regulating Solenoid: Service and Repair Control and Shift Solenoids Replacement Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 2508 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 12601 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 5516 19. Remove the catalytic converter to exhaust manifold nuts (1). 20. Separate the catalytic converter assembly from the exhaust manifolds. 21. Remove the catalytic converter assembly from the exhaust muffler. 22. If replacing the catalytic converter assembly, perform the following steps, otherwise proceed to step 4 in the installation procedure. 23. Remove the exhaust seals (2 and 3). 24. Remove the HO2S (1-4) from the catalytic converter assembly. Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from as exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Page 4902 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 22349 Rear Seat Cushion Outer Trim Panel Replacement (Crew Cab) Rear Seat Cushion Outer Trim Panel Replacement (Crew Cab) Page 23579 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 22133 Power Seat Control Module: Service and Repair Memory Seat Control Module Replacement Page 13039 8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. 9. Inspect the 1-2 accumulator piston for the following conditions: * Porosity * Cracks * Scoring * Nicks and scratches 10. Inspect the 1-2 accumulator cover for the following conditions: * Porosity * Cracks * Scoring * Nicks and scratches 11. Remove the spacer plate support bolts. Important: Use care not to drop the following items that will be removed along with the spacer plate: * The number 1 checkball * The 3-4 accumulator spring * The 3-4 accumulator pin Remove the spacer plate support. Page 4756 1. Install a NEW front cover. Notice: Refer to Fastener Notice. 2. Install the front cover bolts. Tighten the bolts to 12 N.m (106 lb in). Important: Do not reuse the original O-ring seal. 3. If reinstalling the old CMP sensor, install a NEW O-ring seal onto the sensor. 4. Install the CMP sensor to the wiring harness jumper. 5. Connect the CMP sensor wiring harness jumper to the CMP sensor. 6. Lubricate the O-ring seal with clean engine oil. 7. Install the CMP sensor and wiring harness jumper to the engine front cover. 8. Install the CMP sensor bolt. Page 11907 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 7841 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Retractor: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 9198 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 10663 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip (1) from the bracket on the automatic transmission. 9. Unclip the oxygen sensor harness connector from the bracket. 10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 8453 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 23663 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 14928 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 1866 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 10005 5. Remove the EVAP canister purge solenoid valve bolt (1). 6. Remove the EVAP canister purge solenoid valve (2) from the upper intake manifold. 7. Remove the EVAP canister purge solenoid valve O-ring seal (3) from the upper intake manifold, if necessary. Installation Procedure 1. Lubricate the EVAP canister purge solenoid valve O-ring seal with clean engine oil in order to aid with the installation. 2. Install the EVAP canister purge solenoid valve (2) into the upper intake manifold. Notice: Refer to Fastener Notice. 3. Install the EVAP canister purge solenoid valve bolt (1). Tighten the bolt to 10 N.m (89 lb in). Page 17049 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 7126 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 4057 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 6506 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 576 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 5104 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 3925 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 19108 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) 2 - Inflatable Restraint Sensing and Diagnostic Module (SDM) 3 - Inflatable Restraint Vehicle Rollover Sensor (ASF) 4 - Shifter Housing 5 - Rear HVAC Outlet Duct 6 - Rear Object Sensor Control Module (UD7) Driver Door Page 3177 4. Position the knock sensor heat shield to the engine block and install the bolt. Tighten the bolt to 10 N.m (89 lb in). 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. Page 1120 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 8358 High Speed Bus - 1 of 3 Page 5130 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 11797 View of the connector when released from the component. View of another type of Micro 64 connector. Page 3728 Removal Procedure 1. Place drain pans under the vehicle as needed. 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. Notice: Refer to Power Steering Hose Disconnected Notice. 3. Disconnect the power brake booster outlet hose (1) from the power brake booster (2). 4. Disconnect the power brake booster outlet hose (1) from the power steering fluid reservoir (3). 5. Remove the power brake booster outlet hose (1) from the vehicle. Installation Procedure Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 1. Install the power brake booster outlet hose (1) to the vehicle. 2. Connect the power brake booster outlet hose (1) to the power steering fluid reservoir (3). 3. Connect the power brake booster outlet hose (1) to the power brake booster (2). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Page 1943 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 5819 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Locations Discharge Air Temperature Sensor / Switch: Locations HVAC Component Views Upper Front Air Temperature Sensors (CJ2) 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right HVAC Module Page 13538 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 23110 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 24453 For vehicles repaired under warranty, use the table. Disclaimer Page 6629 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 18096 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 3867 Fuse Block - I/P, Device Usage Left I/P Junction Block Page 6866 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 18432 Page 999 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 2115 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 9919 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Displays and Gages Connector End Views Driver/Vehicle Information Display: Diagrams Displays and Gages Connector End Views Displays and Gages Connector End Views Driver Information Center (DIC) Switch Page 5854 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 8121 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 22986 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 21628 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 12254 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 12015 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. Page 18900 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 6957 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 2126 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 10456 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 9057 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 12771 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 18019 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 8169 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 2743 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 3131 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 288 Memory Seat Module X6 (AN3) Page 6798 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 16743 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 9244 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (7) from the camshaft position (CMP) sensor wiring harness jumper. 2. Remove the water pump. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor and wiring harness jumper from the engine front cover. 5. Disconnect the CMP sensor wiring harness jumper from the CMP sensor. 6. Remove the CMP sensor from the wiring harness jumper. Installation Procedure Page 2182 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 8595 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 608 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 17744 Steering Angle Sensor: Removal and Replacement Steering Wheel Position Sensor Replacement Page 11822 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 15932 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 7181 Page 2626 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 14080 3. Install one bolt marked (1) to hold the control valve assembly in place. Notice: Refer to Fastener Notice. 4. Reinstall the remaining 10 bolts marked (1) and 4 bolts marked (2) that fasten the control valve assembly to the transmission case. Tighten the bolts to 12 N.m (108 lb in). 5. Push the transmission main connector outward through the hole in the transmission case until the retaining feet on the connector are nearing the locked position. Page 18185 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Page 18911 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Crew Cab -10 Series) Page 4869 Coolant Reservoir: Service and Repair Radiator Surge Tank Replacement Radiator Surge Tank Replacement (Non-HP2) Page 7152 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 16753 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 20037 Speaker: Diagrams Entertainment/Communication Connector End Views Speaker - Center (UQA +Y91) A/T Shift Lock Control Solenoid Speaker - Left Front (UQ5) A/T Shift Lock Control Solenoid Speaker - Left Front (UQ3) Page 4957 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 6340 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 21892 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 15018 Fluid Pressure Sensor/Switch: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 10813 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 12375 Transmission Mode Switch: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Internal Mode Switch (IMS) Internal Mode Switch (IMS) Page 14174 Align the reference marks made during removal. 11. Install the propeller shaft yoke retaining clamps and the bolts. Tighten the propeller shaft yoke retaining clamp bolts to 25 N.m (18 lb ft). 12. Install the axle shafts (10.5 inch, 11.5 inch axle). 13. Install the brake rotors (8.6 inch, 9.5 inch axles). 14. Install the brake calipers (8.6 inch, 9.5 inch axles). 15. Install the tire and wheel assemblies. 16. Inspect and add axle lubricant to the axle housing, if necessary. 17. Lower the vehicle. Page 6267 Page 9863 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 24721 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 5156 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 9330 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 6098 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 2466 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 4092 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 11972 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 6623 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 21565 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 18121 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 6463 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Allison - Automatic Transmission Seals and Gaskets: Service and Repair Allison - Automatic Transmission Manual Shift Shaft Seal Replacement Manual Shift Shaft Seal Replacement Tools Required * J 43911 Manual Shift Shaft Seal Remover * J 43909 Manual Shift Shaft Seal Installer Removal Procedure 1. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the manual shift shaft (2) with the threaded end of the tool towards the seal. 2. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell. 3. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed. Installation Procedure 1. Carefully slide a new manual shift shaft seal (1) over the manual shift shaft (2) with the wide face of the steel case facing outward. Position so that the seal is starting to enter the seal bore. Page 16121 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 8944 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 19462 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Page 8206 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 21693 Driver Door Switch (DDS) X4 (AN3) Page 5481 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 5431 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 8762 Body Control Module: Service and Repair Body Control Module Bracket Replacement Body Control Module Bracket Replacement Page 22141 Seat Lumbar Horizontal Motor - Passenger (AN3) Telescoping Actuator C1 Seat Lumbar Vertical Motor - Driver (AN3) Telescoping Actuator C1 Page 9699 Page 11310 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 6490 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 9636 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 20594 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 17241 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Diagrams Ignition Relay: Diagrams Engine Electrical Connector End Views Run Relay (TP2) Run Relay (TP2) Page 24697 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 7043 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 22410 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 14715 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the oil level indicator. 2. Remove the right exhaust manifold. 3. Remove the oil level indicator tube bolt. 4. Remove the oil level indicator tube using a twisting motion. 5. Clean the old sealer from the indicator tube and engine block. Installation Procedure 1. Apply sealant around the indicator tube 13 mm (0.5 in) below the tube bead. Refer to Sealers, Adhesives, and Lubricants for the correct part number. 2. Install the indicator tube. Rotate the oil level indicator tube into position. Notice: Refer to Fastener Notice. 3. Install the indicator tube bolt. Tighten the bolt to 12 N.m (106 lb in). Page 24734 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 14842 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 22459 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 8140 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 5359 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 14103 4. Inspect the wiring harness along the left side frame rail at the body mounts for chafed/shorted wiring as shown. 5. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness Near Data Link Resistor Chafed Wiring Harness Near Data Link Resistor Causing Intermittent No/Crank and/or Scan Tool Does Not Communicate with High Speed GMLAN Device 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Typical location of a data link resistor (3) mounted on the chassis. Page 7178 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. HVAC - Automatic Low Pressure Sensor / Switch: Locations HVAC - Automatic HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 5408 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 5021 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 1174 and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 6. Connect a test lamp between the relay coil B+ and the relay coil control circuit. 7. Ignition ON, command the powertrain relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the relay coil control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the relay coil control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 8. Connect a 20A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 9. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 10. If all circuits test normal, test or replace the relay. Component Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Test for 65-110 ohms of resistance between terminals 85 and 86 of the relay. ‹› If the resistance is not within the specified range, replace the relay. 3. Test for infinite resistance between following terminals: * Terminal 30 and 86 * Terminal 30 and 87 * Terminal 30 and 85 * Terminal 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 20A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm of resistance between terminals 30 and 87. ‹› If greater than the specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Relay Replacement (Within an Electrical Center) Relay Replacement (Attached to Wire Harness) * Underhood Electrical Center or Junction Block Replacement * Refer to Programming and Relearning for setup and programming. See: Testing and Inspection/Programming and Relearning Page 9407 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. Page 19522 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 3931 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 24316 Power Window Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 5268 Page 7850 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 9252 lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If re-installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. Notice: Refer to Fastener Notice. 2. Install the ECT sensor to the cylinder head. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 21512 Body Lock Pillar Trim Replacement (Regular Cab) Body Lock Pillar Trim Replacement (Regular Cab) Page 10143 * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Page 9234 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 12975 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 13553 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 9631 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 9318 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 21153 For vehicles repaired under warranty, use the table. Disclaimer Page 7233 View of the connector when released from the component. View of another type of Micro 64 connector. Page 9575 Page 11434 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 15615 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 1967 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 1639 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 16499 X800 Right Rear Door Harness to Body Harness (Extended Cab) Page 17336 X415 Inline Harness Connector End Views X415 Rear Bumper Harness to Left Hip Lamp Harness (RO5) Page 23634 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 12534 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 8223 Fuel Tank Pressure Sensor: Diagrams Engine Controls Connector End Views Fuel Tank Pressure (FTP) Sensor Page 4038 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 1097 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 10488 Fuel Injector: Testing and Inspection Fuel Injector Diagnosis (With J 39021 or Tech 2) Fuel Injector Diagnosis (With J 39021 or Tech 2) Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. When performing the fuel injector balance test, the scan tool is first used to energize the fuel pump relay. The fuel injector tester or the scan tool is then used to pulse each injector for a precise amount of time, allowing a measured amount of the fuel to be injected. This causes a drop in the system fuel pressure that can be recorded and used to compare each injector. Diagnostic Aids * Monitoring the misfire current counters, or misfire graph, may help to isolate the fuel injector that is causing the condition. * Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. * Perform the fuel injector coil test within the conditions of the customer's concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. Component Testing Fuel Injector Coil Test Verify the resistance of each fuel injector with one of the following methods: * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14 ohms. ‹› If the injectors measure OK, perform the Fuel Injector Balance Test - Fuel Pressure Test. ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value. The difference between the lowest value and the highest value should be equal to or less than 3 ohms. ‹› If the difference is equal to or less than 3 ohms, refer to Fuel Injector Balance Test - Fuel Pressure Test for further diagnosis of the fuel injectors. ‹› If the difference is more than 3 ohms, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. Important: * DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling. * Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. Fuel Injector Balance Test-Fuel Pressure Test 1. Install a CH-48027. 2. Turn ON the ignition, with the engine OFF. Page 1589 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor from the cylinder head. Installation Procedure Notice: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, Page 4745 performance. Important: The reluctor ring is shaped like a dish. The dish must face the engine front cover. Failure to do so will damage the front cover and the reluctor ring. 1. Install the CKP sensor reluctor ring. 1. Align the keyway on the CKP sensor reluctor ring with the key in the crankshaft. 2. Using J 5590, push the CKP sensor reluctor ring onto the crankshaft until completely seated against the crankshaft sprocket. 2. Install the engine front cover. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Cooler: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Fluid Auxiliary Cooler Replacement Removal Procedure 1. Remove the front grill assembly. 2. Place a drain pan under the vehicle. 3. Disconnect the transmission oil cooler lines from the auxiliary cooler. 4. Remove the auxiliary oil cooler bolts (1) and push pins (2). 5. Remove the auxiliary oil cooler from the vehicle. Installation Procedure 1. Install the auxiliary oil cooler to the vehicle. Notice: Refer to Fastener Notice. 2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. Tighten the bolts to 12 N.m (9 lb ft). 3. Connect the transmission oil cooler lines to the auxiliary cooler. 4. Install the front grill assembly. Page 11317 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Diagram Information and Instructions Door Module: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 14293 Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Tools Required * J 8059 Snap Ring Pliers * J 35910 Drive Axle Seal Clamp Pliers * J 36652-1 Drive Axle Clamp Swage Tool * J 36652-2 Axle Swage Tool Removal Procedure 1. Remove the wheel drive shaft. 2. Remove the wheel drive shaft seal cover, if applicable. Important: Use caution when using the hand grinder by the CV joint outer race (1). 3. Use a hand grinder to cut through the swage ring (2). 4. Use side cutters to cut off the small boot clamp (4). Page 21936 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 6931 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 13589 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7264 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 11339 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 2036 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 23604 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 11094 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 13309 Page 15692 Page 3192 1 - Door Frame 2 - Window Switch - Driver (A31 -AN3/DL3) 3 - Outside Rearview Mirror - Driver 4 Memory/Heated Seat Switch (AN3) 5 - Outside Rearview Mirror Switch (DL8/DPN) 6 - Driver Door Switch (DDS) (AN3/DL3) 7 - Speaker - Left Front 8 - Window Motor - Driver (A31) 9 - Door Lock Switch - Driver (AU3 -AN3/DL3) 10 - Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) 11 - Door Latch Assembly - Driver Passenger Door Page 8489 Page 3405 Transmission Speed Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 24218 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 24511 All checks must include the complete 17 character Vehicle Identification Number. ^ Fleet Customer - Daily Rental (Avis, Budget, Enterprise, etc.) Issue check to the daily rental company if valid proof of vehicle ownership documentation is available. Confirm local address and mail or provide check to their representative at vehicle pickup. All checks must include the complete 17 character Vehicle Identification Number. ^ Fleet Customer - Lease Management Company (PH&H;, GE Capital, ARI, etc.) Issue check to the lease management company if valid proof of ownership documentation is available. Ask the customer where the check should be mailed. Approximately 7,500 vehicles are involved and these customers will be receiving a letter from their lease management company explaining this situation. All checks must include the complete 17 character Vehicle Identification Number. Q12. What should I do if a customer refuses to have the recall service procedure performed on his/her vehicle? A12. If a customer initially declines the recall repair, please make sure that he/she fully understands the possible consequences. Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. General Motors has decided that a defect that relates to motor vehicle safety exists in certain 2006-2009 model year Buick Lucerne; Cadillac DTS; HUMMER H2; 2008-2009 model year Buick Enclave; Cadillac CTS; 2007-2009 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL; Saturn OUTLOOK; and 2009 model year Chevrolet Traverse vehicles equipped with a heated washer fluid system (HWFS). As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products. Important - Your vehicle is involved in safety recall 10153. - Schedule an appointment with your GM dealer/retailer. - This service will be performed for you at no charge. Why is your vehicle being recalled? A recall was implemented on some vehicles in 2008 to add a fuse to the HWFS control circuit harness to address the potential consequences of a printed circuit board electrical short. However, there have been new reports of thermal incidents on HWFS modules after this improvement was installed. These incidents resulted from a new failure mode attributed to the device's thermal protection feature. Their significance varies from minor distortion to considerable melting of the plastic around the HWFS fluid chamber. In some circumstances, it is possible for the heated washer module to cause a fire. What will we do? Your GM dealer/retailer will permanently disable and remove the heated washer fluid system. In addition, because the heated washer feature will be disabled, the dealer will provide a customer satisfaction payment of $100 to the customer. This service will be performed for you at no charge. Because of service scheduling requirements, it is likely that your dealer/retailer will need your vehicle longer than the actual service correction time of approximately 20 minutes. An updated page for your Owner Manual will be provided and inserted at the time of service to document that the feature has been permanently disabled and removed from your vehicle. If your vehicle is within the New Vehicle Limited Warranty, your dealer/retailer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership/facility for this repair. Please refer to your Owner Manual and your dealer/retailer for details on courtesy transportation. What should you do? You should contact your GM dealer/retailer to arrange a service appointment as soon as possible. Did you already pay for this repair? The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition. Even though you may have already had this condition repaired in the past, you will still need to take your vehicle to your dealer/retailer for this recall. Locations Electronic Brake Control Module: Locations Antilock Brake System Component Views Left Side of the Engine Compartment 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (- MYC) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Page 20097 Disclaimer Page 9574 Oxygen Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 1229 Auxiliary Battery Relay: Diagrams Auxiliary Battery Relay X1 (TP2) Auxiliary Battery Relay X1 (TP2) Page 5036 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10555 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 1776 Page 13619 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 11818 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 2767 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Seats - Driver/Passenger Heated Seats Inop./Slow to Warm Seat Fan: Customer Interest Seats - Driver/Passenger Heated Seats Inop./Slow to Warm TECHNICAL Bulletin No.: 10-08-50-008B Date: January 13, 2011 Subject: Driver or Passenger Heated Seat Inoperative, Slow to Warm, DTC(s) Set (Repair Connector, Re-Route Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Silverado, Suburban, Tahoe 2011 Chevrolet Silverado Heavy Duty 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2011 GMC Sierra Heavy Duty All Equipped with Heated Front Seat (RPO AN3, KA1) or Heated and Cooled Seat (RPO KB6) and/or Luxury Package (RPO PCK) Supercede: This bulletin is being revised to update the RPOs. Please discard Corporate Bulletin Number 10-08-50-008A (Section 08 - Body and Accessories). Condition Some customers may comment that the driver or passenger heated seat system exhibits the following symptoms: - Heated seat turns on and then turns off within 1 to 10 minutes (at any 60 second interval). - The system doesn't get warm enough, or gets warm very slowly. - The heated seat system is completely inoperative. Upon further review, DTCs B2430 0D and/or B2180 0D may be set as a current or history code if the vehicle is equipped with heated seats only (RPO KA1). Also, the LED indicator for the heated seats may come On and then flash after approximately 1 minute, then go out. If the vehicle is equipped with heated and cooled seats (KB6), the switch LED indicator may stay On, but the heated and cooled seat is inoperative. The fan will continue to blow air. Cause Heated Seats (RPO AN3, KA1) The heated seat control circuit terminal and/or ground terminal in harness connector X1 to the memory seat module (MSM) may have lost tension and is loose. The reduced terminal tension increases resistance in the connector, which may result in the symptoms described above. Heated and Cooled Seats (RPO KB6) The thermo-electric device (TED) in the seat cushion/seat back ventilation heating and cooling module may have become inoperative. Correction Heated Seats (RPO AN3, KA1) Follow the steps below to correct the concern with the heated seats. Note This repair requires a unique anti-abrasion electrical tape and harness clip from Kent Automotive. Refer to the Parts Information below. 1. Access and remove the seat bolts/nuts. 2. Adjust the seat rearward about halfway. Adjust the seat recline full forward. 3. Tilt the seat backward to access the bottom of the seat. Prop the seat up with a suitable tool if required. Page 7870 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 943 Engine Controls - Cruise Control Turns Off When Operated Cruise Control: Customer Interest Engine Controls - Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 11259 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 11309 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 6880 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 2949 Page 14888 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 18607 Control Module HVAC: Service and Repair Blower Motor Control Module Replacement Page 17552 Disclaimer Page 8045 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 18458 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 20282 Parking Assist Distance Sensor: Diagrams Object Detection Connector End Views Object Sensor - Left Rear Corner Object Sensor - Left Rear Middle Page 5019 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 2625 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Locations Parking Brake Warning Switch: Locations Hydraulic Brake Component Views 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Page 23910 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 327 For vehicles repaired under warranty, use the table. Disclaimer Page 5173 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 2981 View of the connector when released from the component. View of another type of Micro 64 connector. Page 20949 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7815 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 14008 Page 2639 View of the connector when released from the component. View of another type of Micro 64 connector. Page 22985 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 10912 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Fuse Block - I/P, Top View Fuse: Application and ID Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Label Page 11967 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 1096 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 21276 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 4630 Tighten the bolts/nuts to 100 N.m (74 lb ft). 10. If equipped, install the engine protection shield. Refer to Engine Shield Replacement. 11. Remove the jack or utility stand from the rear of the vehicle. 12. Lower the vehicle. Important: * Ensure the oil cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap onto the cooler line prior cooler line installation. * Do not use the plastic cap in order to install the cooler line into the fitting. If equipped with RPO LY6 (6.0L) engine, install the oil cooler hoses to the clip. Important: Locations Heated Glass Element Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 6919 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 9539 Page 14895 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 12642 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 12798 Page 1498 Disclaimer Page 3403 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 2272 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7638 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 19866 Page 6373 Crankshaft Position Sensor: Connector Views Engine Controls Connector End Views Crankshaft Position (CKP) Sensor Page 4949 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Allison - Automatic Transmission Control Module: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views A/T - MIL ON/DTC P0751 Is Stored In Memory Valve Body: Customer Interest A/T - MIL ON/DTC P0751 Is Stored In Memory TECHNICAL Bulletin No.: 07-07-30-031D Date: February 20, 2009 Subject: Malfunction Indicator Lamp (MIL) On - Check Engine Light, DTC P0751 (Diagnose and Repair as Necessary) Models Supercede: This bulletin is being revised to provide additional information on the new spacer plate. Please discard Corporate Bulletin Number 07-07-30-031C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a malfunction indicator lamp (MIL) being illuminated. A scan tool may reveal DTC P0751 set in the TCM as current or in history. Correction Follow the service instructions below based on the group your vehicle is in. 2007 Silverado or Sierra with 6L90 Transmission (MYD) 1. Inspect and note the transmission fluid level and condition. If the level is high or low, it should be corrected and the vehicle road tested to verify that the condition is still present. 2. Remove the transmission bottom pan to inspect for possible debris. ^ If debris is found, the transmission should be disassembled to determine the source. Repair or replace the transmission in the most economical method following guidelines in Corporate Bulletin # 02-07-30-029. ^ If no debris is noted in the oil pan, remove the control valve body assembly and proceed to the next step. 3. Disassemble the valve body to: Page 700 Disclaimer Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: Customer Interest Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 13058 For vehicles repaired under warranty, use the table. Disclaimer Page 10943 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 15286 Front Brake Rotor Replacement (JH6, JH7) Front Brake Rotor Replacement (JH6, JH7) Page 22959 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 6275 Crankshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 12144 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 19032 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10512 4. Prior to removal, clean the fuel meter body with a spray type engine cleaner, such as GM X-30A, or equivalent, if necessary. Follow the package instructions. Do not soak the fuel meter body in liquid cleaning solvent. Important: When removing the injectors, mark the injectors with tape and their corresponding cylinder number in order to ensure correct injector placement upon installation. 5. Lightly pull on the fuel injector tube, and using a small pocket screwdriver, remove the fuel injector from the lower intake manifold bore. Important: During the removal of the fuel meter body, the retainers that hold the injectors into the intake manifold may become worn. This is OK. Upon installation of the intake manifold, the injectors will be held fully seated, thus keeping them from backing out of the lower intake manifold. 6. Remove the other 5 fuel injectors from the lower intake manifold bores. Notice: Cover the injector sockets in order to prevent dirt and other contaminants from entering the open fuel passages. 7. Remove the fuel meter body from the vehicle. Installation Procedure Important: All injector lines must face forward as the fuel meter body is snapped into the bracket. Also, the number 3 fuel tube must be positioned behind the number 1 fuel tube in order to eliminate interference with the upper intake manifold when installed. 1. Position the fuel tubes of the fuel meter body in the forward position. 2. Install the fuel meter body into the fuel meter body bracket on the lower intake manifold. 3. Install the 6 injectors into the proper lower intake manifold bores in proper sequence (5, 1, 3, 2, 4, 6). 4. Inspect the injectors in order to ensure that they are firmly seated and locked in the lower intake manifold bores. 5. Ensure that the electrical connections of the injectors are positioned so that they do not interfere with each other, and are pointing towards the center of the intake manifold. Rotate the electrical connections inboard if necessary. Also, ensure there is no tension on the injector wires. 6. Install the upper intake manifold. 7. Tighten the fuel fill cap. 8. Connect the negative battery cable. 9. Test for fuel leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. 4. Inspect for fuel leaks. Page 19763 Method 1 Method 2 Page 17107 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 2897 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 8082 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 11077 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 9923 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 5946 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 7912 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 9712 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 16977 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 13781 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 5145 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 12634 4. Install the reverse signal pipe. Install the 2 bolts that fasten reverse signal pipe to the control valve assembly. Tighten the bolts to 12 N.m (108 lb in). 5. Reconnect the internal wiring harness to the solenoid. 6. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Control Valve Solenoid Replacement (SS1, SS2, SS3, TCC, and MAIN MOD) Removal Procedure 1. Remove the oil pan and the transmission internal oil filter. 2. Disconnect the internal wiring harness from the solenoid being changed. 3. Remove the solenoid retainer (2) for shift solenoid 1 (SS1) (5). Note the position of the solenoid connector and pull the solenoid (5) out of the bore in the control valve assembly (1). The O-rings (3 and 4) provide the resistance felt during removal. Page 11581 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 21642 Door Module: Electrical Diagrams Door Control Module Schematics Power, Ground and Serial Data Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Transmission Fluid Temperature Sensor Specifications Page 9697 Page 11341 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 5273 Vehicle Zoning Strategy Truck Zoning 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 1368 1 - Door Lock Switch - Passenger 2 - Door Latch Assembly - Passenger 3 - Speaker - Right Front Page 20654 5. Install the new roll pin that is included in the door handle kit, P/N 88880051. 6. Install the rear side door inside handles. Refer to Rear Side Door Inside Handle Replacement in SI. Customer Information 1. Submit a claim using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Customer Reimbursement - For US All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers. A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter. Important Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form. Customer Reimbursement - For Canada Customer requests for reimbursement of previously paid repairs to correct the condition covered under this Special Coverage are to be submitted to the dealer prior to or by July 31, 2011. Repairs must have occurred within 10 years of the date the vehicle was originally placed in service. When a customer requests reimbursement, they must provide the following: - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Disclaimer Page 5447 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 22151 11 - Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) 12 - Seat Adjuster Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Passenger Seat 1 - Seat Frame 2 - X325 (AN3) 3 - Seat Lumbar Vertical Motor - Passenger (AN3) 4 - Seat Adjuster Switch - Passenger (AG2) 5 - Seat Lumbar Switch - Passenger (AN3) 6 - Seat Belt Buckle Passenger 7 - Inflatable Restraint Passenger Presence System (PPS) Module (AL0) 8 - Seat Adjuster Assembly - Passenger (AG2) 9 - Inflatable Restraint Passenger Presence System (PPS) Sensor (AL0) 10 - Seat Recline Motor - Passenger (AN3) 11 - Seat Lumbar Horizontal Motor Passenger (AN3) Interior - Ashtray Door Will Not Close Ash Tray: Customer Interest Interior - Ashtray Door Will Not Close TECHNICAL Bulletin No.: 08-08-49-009 Date: April 18, 2008 Subject: IP Ashtray Door May Not Close (Replace Pivot Pins) Models: 2007-2008 Chevrolet Silverado (Except Uplevel Trim LTZ) 2007-2008 GMC Sierra (Except Uplevel Trim SLT) with Base Instrument Panel Condition Some customers may comment that the instrument panel (IP) ashtray door may not close. Cause The pivot pins may have insufficient retention, allowing the ashtray door to come off the pivot bar. Correction A new service pivot pin is now available. Install two new pivot pins (1) using the steps below. 1. Remove the ashtray door assembly from the IP. Refer to Ashtray Replacement in SI. 2. Holding the ashtray assembly in your hand, grab the pivot pin and slide the pin out from the bottom side of the ashtray T-slot (1). 3. Install the new pivot pin into the T-slot of the ashtray. 4. Slide the pin tab into the T-slot until the pin tabs lock into place. 5. Repeat Steps 2-4 for the opposite side pivot pin. 6. Install the ashtray assembly back into the IP by seating the pivot pins onto the pivot bar and closing the door. 7. Cycle the ashtray door three complete times to verify that the condition has been corrected. Parts Information Warranty Information Page 7995 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 14618 Transmission Position Switch/Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft Position Switch Replacement Page 2112 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 10141 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Page 21143 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Page 22505 Page 16751 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 581 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 1633 Low Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Low Pressure Switch Replacement (Non-HP2) Removal Procedure 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. Installation Procedure 1. Install the new O-ring seal to the switch. Notice: Refer to Fastener Notice. 2. Install the A/C low pressure switch to the accumulator. Tighten the switch to 6 N.m (53 lb in). 3. Connect the electrical connector to the A/C low pressure switch. 4. Leak test the fittings of the components using the J 39400-A. Page 4252 Important: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 3. Mount the tire to the rim. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 24745 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Locations Crankshaft Position Sensor: Locations Engine Controls Component Views Right Side of Engine 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 17610 Tire Pressure Module: Service and Repair Control Module Setup Remote Control Door Lock Receiver (RCDLR) Setup After remote control door lock receiver assembly replacement, the following procedures must be performed in the order that they appear for the tire pressure monitor (TPM) System to function properly. The RCDLR also requires keyless entry transmitter programming after replacement. Refer to Transmitter Programming. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool select Vehicle Control System. 4. Select Module Setups. 5. Select Remote Control Door Lock Receiver. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle drivers door placard sticker. 9. Select the rear tire pressure as noted on the vehicle drivers door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After RCDLR assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the RCDLR memory. Refer to Tire Pressure Sensor Learn. Page 7112 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 15340 Page 15359 * Scoring in the caliper bores * Corrosion in the caliper bores * Pitting in the caliper bores * Damage to the pistons (phenolic) 15. Clean the brake caliper assembly with denatured alcohol. 16. Dry with filtered, non-lubricated compressed air. Assembly Procedure Important: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material. 1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore. 2. Install the square-cut piston seal in the brake caliper bore groove. 3. Ensure the square-cut piston seal is not twisted. Page 11831 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 3882 Page 22955 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 3581 Disclaimer Page 5856 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 3409 Transmission Speed Sensor: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Automatic Transmission Input Speed Sensor (AT ISS) Automatic Transmission Turbine Speed Sensor Page 22936 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12802 Page 14669 1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission. 2. Install the pass-through electrical connector to the transmission case. Notice: Refer to Fastener Notice. 3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. * Tighten the control valve body bolts to 11 N.m (97 lb in). * Tighten the TCC solenoid bolts to 11 N.m (97 lb in). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. Page 17410 1. Install the relay (2) in the same position as removed. 2. Install the electrical center cover. Parking Brake Actuator Replacement (JD9) Parking Brake Actuator: Service and Repair Parking Brake Actuator Replacement (JD9) Parking Brake Actuator Replacement (JD9) Page 14893 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 5193 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 10468 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 5583 6. If vehicle has a crew cab, remove the exhaust heat shield nuts. 7. Remove the exhaust front heat shield (1) and/or the rear exhaust heat shield (2) from the studs. Installation Procedure 1. If vehicle has a crew cab, position and install the rear exhaust heat shield (2) and/or the front exhaust heat shield (1) to the underbody studs. Notice: Refer to Fastener Notice. 2. Install the exhaust heat shield nuts. Tighten the nuts to 9 N.m (80 lb in). Page 6681 Oxygen Sensor: Connector Views Engine Controls Connector End Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Page 6553 Notice: Refer to Fastener Notice. 1. Position the knock sensor to the engine block and install the bolt. Tighten the bolt to 25 N.m (18 lb ft). 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (2) up and over the knock sensor. Page 18209 Air Door Actuator / Motor: Service and Repair HVAC - Manual Air Temperature Actuator Replacement Air Temperature Actuator Replacement Air Temperature Actuator Replacement - Right Side Air Temperature Actuator Replacement - Right Side Page 7978 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 12895 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 10273 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 23058 Vehicle Zoning Strategy Truck Zoning Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Antenna Cable: Service and Repair Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Radio Antenna Cable Extension Cable Replacement (without RPO SLT) Page 4944 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing Tools required * J 24460-01 Cooling System Pressure Tester * J 42401 Radiator Cap / Surge Tank Test Adapter Pressure Cap Testing Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: * Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. * Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: * The pressure cap does not release pressure which exceeds the rated pressure of the cap. * The pressure cap does not hold the rated pressure. Page 8422 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 18030 Important: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 3. Mount the tire to the rim. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 13955 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 13613 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 598 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 13782 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 2102 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 7575 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 10224 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 12070 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 10246 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 15819 Page 1266 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 7142 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 12062 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 10542 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 2836 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 2509 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 21236 For vehicles repaired under warranty, use the table above. Disclaimer Page 1850 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 1987 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 18487 9. Remove the outlet heater hose. Installation Procedure 1. Install the outlet heater hose. 2. Install the outlet heater hose to the water pump. 3. Install the outlet heater hose to the surge tank. 4. Install the outlet heater hose clamp to the surge tank. 5. Connect the heater and surge tank hoses to the heater core. Important: Firmly push the quick connect onto the heater core hose until you hear an audible click. 6. Pull the heater outlet hose to ensure the connection. 7. Install the heater and surge tank hoses to the mounting clip. Page 1144 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 3138 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 23911 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21088 Locations Driver/Vehicle Information Display: Locations Displays and Gages Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 24198 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 14100 7. Inspect how the IP branch to C202 is routed. Reroute the harness as necessary to match the correct routing in the photo as shown. In order to route the IP harness branch correctly (behind the junction block-left I/P), remove the cover from the junction block-left I/P, unseat the junction block from the bracket. 8. Disconnect C202. Route the harness such that it lies between the "goalposts" of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). 9. Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 11. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed IP Wiring Harness at Left Side Junction Block Mounting Bracket 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Remove the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 4. Inspect for chafed/shorted wiring at the mounting bracket. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Replace the left side junction block. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side in SI. 7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 8. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Adjustable Pedals Motor 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Inspect the wiring harness for chafed/shorted wiring at the adjustable pedals motor as shown. 4. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 5. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 7. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness at Transmission 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Support the transmission with a transmission jack. 5. Remove the transmission support crossmember. Refer to Transmission Support Crossmember Replacement in SI. Page 6850 Page 7636 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 2629 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 708 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 9651 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 2890 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14468 Flex Plate: Service and Repair Engine Flywheel Replacement Removal Procedure 1. Remove the automatic transmission. 2. Remove the flywheel bolts. 3. Remove the flywheel (1 or 2). 4. Clean and inspect the flywheel, if necessary. Refer to Engine Flywheel Cleaning and Inspection. Installation Procedure Flywheel Important: Flywheel weights of the same length must be installed into the NEW flywheel in the same location as the old weights were in the old flywheel. 1. Note the position of the old flywheel weights and install the NEW flywheel weights as required. A properly installed flywheel weight will be flush or slightly below flush with the face of the flywheel. 2. Install the flywheel (1 or 2). Align the flywheel locator hole to the flywheel locator pin. Page 15857 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Vehicle Speed Sensor Assembly, Wiring Harness Side Page 4132 Junction Block - Left I/P X12 Page 24459 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 6816 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Page 4318 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 21988 Sunroof / Moonroof Switch: Diagrams Sunroof Connector End Views Sunroof Switch Page 13406 Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 24108 1. Remove the instrument panel (I/P) knee bolster. Refer to Knee Bolster Replacement in SI. 2. Remove the park brake release handle. Refer to Park Brake Release Handle Assembly Replacement SI. 3. Locate the left bussed electrical center (LBEC), which is located on the left end of the instrument panel IP. 4. Locate the 40-way connector X1 that is attached to the back of the LBEC. 5. Disconnect the 40-way connector X1 from the LBEC. Page 3110 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 22018 Sunroof / Moonroof Module: Diagrams Sunroof Connector End Views Sunroof Module Page 7198 Vehicle Zoning Strategy Truck Zoning Page 11732 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 17302 X203 Inline Harness Connector End Views X203 Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) to Headliner Harness (UE1/U3U/UVB) Page 21588 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 1998 Page 6156 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 10318 For vehicles repaired under warranty, use the table above. Disclaimer Page 10751 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 2747 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 15762 3. Install the positive battery cable channel at the plenum front panel. 4. Install the positive battery cable clips to the studs on the plenum front panel. 5. Install the starter solenoid cable (1) terminal to the mega fuse stud. Notice: Refer to Fastener Notice. 6. Install the starter solenoid cable nut (2) to the mega fuse. Tighten the nut to 9 N.m (80 lb in). Page 11844 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 17790 Steering Shaft: Service and Repair Steering Shaft Lower Bearing Replacement Steering Shaft Lower Bearing Replacement Page 13780 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 12829 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 472 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 2445 Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (2). Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S pigtail electrical connector (5) to the engine wiring harness electrical connector (4). 4. Install the CPA retainer. 5. Lower the vehicle. Page 17482 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10770 Page 3600 Disclaimer Page 4041 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 3481 Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Page 16106 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 979 View of the connector when released from the component. View of another type of Micro 64 connector. Page 7944 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 17564 For vehicles repaired under warranty, use the table. Disclaimer Page 20103 Disclaimer Page 10664 11. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 12. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. 14. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. 15. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 16. Unclip the inline harness connector from the bracket. 17. Remove the fuel line bracket bolt (1). 18. Remove the fuel/EVAP line clip nut (2). 19. Loosen the brake pressure modulator valve (BPMV) bolts. Slide the BPMV off of the frame and reposition the BPMV without disconnecting the brake lines. 20. Unclip the line assembly from the frame. 21. Remove the fuel/EVAP line clips from the frame and crossmember. 22. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Page 6070 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11406 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 23635 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 10628 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 7200 Crankshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Brakes - Aftermarket Trailer Brake Controllers Trailer Brake Control Module: All Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 5007 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14248 13. Remove the retaining ring from the wheel hub. 14. Using the J 24426 installer (2) and the J 8092 handle (1), remove the outer hub bearing and bearing cup. Page 10826 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21961 Luggage Rack: Service and Repair Luggage Carrier Rivet Nut Replacement Luggage Carrier Rivet Nut Replacement Removal Procedure 1. Remove the luggage carrier. Refer to Luggage Carrier Replacement . Caution: Refer to Safety Glasses Caution . 2. Drill through the luggage carrier rivnut head using a 7.5 mm (0.295 in) drill bit. 3. Remove the rivnut from the roof. Installation Procedure 1. Using a 10 mm (0.3937 in) drill bit, drill the rivnut hex shape hole in the roof out to a round 10 mm hole. 2. Install a replacement rivnut to the hole in roof using a rivnut tool, or equivalent. 3. Install the luggage carrier. Refer to Luggage Carrier Replacement . X100 - X199 Multiple Junction Connector: Diagrams X100 - X199 X100 Inline Harness Connector End Views X100 Forward Lamp Harness to Left Front Headlamp Harness X103 Page 3988 Fuse: Application and ID Junction Block - Left I/P, Label Electrical Center Identification Views Junction Block - Left I/P, Label Page 24433 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Extended Cab, Power) Rear Side Door Window Regulator Replacement (Extended Cab, Power) Page 16723 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 12764 10. Using J 28458, release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. 12. Inspect the TCC solenoid and wiring harness for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Page 11805 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 11704 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 3945 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 17638 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: All Technical Service Bulletins Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 2827 Page 13569 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 20855 For vehicles repaired under warranty, use the table above. Disclaimer Page 6224 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 2268 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 22920 Page 20309 Page 21120 Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement (Silverado Sierra 2500) Front Side Door Emblem/Nameplate Replacement (Silverado Sierra 2500) Page 1199 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 23089 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 23822 Disclaimer Page 22777 Vinyl contains unique thermal properties that cause it to expand in cold conditions and retract during hot conditions. Under recommended install temperatures of 21°C (70°F), the tension screws should be adjusted as shown below. Important Be sure to adjust both sides to the same tension. 3. Inspect and verify that the tension screws are adjusted to the 4.76 mm (3/16 in) gap shown in the illustration above. If adjustment is necessary to tighten, turn the screw clockwise with the 1/4 inch key provided. Cause #4 The condition may be caused by over travel of the latch during operation, causing the latch spring to bind. Correction #4 Note A new design of the latch system now contains a latch stop (1) to limit the travel of the latch during operation. This new latch stop prevents over travel and keeps the spring from binding. Verify that the latch system contains a latch stop, noted in the illustration above. If the stop IS NOT present, replace the latch system with latch spring stop service kit, P/N 19213898 and a new latch assembly service kit, P/N 19201885. Warranty Information A/C - Compressor/Serpentine Belt Noise PROM - Programmable Read Only Memory: Customer Interest A/C - Compressor/Serpentine Belt Noise TECHNICAL Bulletin No.: 07-01-38-010A Date: October 06, 2009 Subject: Air Conditioning (A/C) Compressor and/or Serpentine Belt Noise at Vehicle Start-up (Reprogram Powertrain Control Module (PCM)) Models: 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon Models Equipped With Air Conditioning (RPOs CJ2 or CJ3) Supercede: This bulletin is being revised to update the Condition and Correction information. Please discard Corporate Bulletin Number 07-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on air conditioning (A/C) compressor slugging and/or serpentine belt or pulley rattle noise at vehicle start-up in warmer outside ambient temperature conditions. Others may describe the noise as a belt chirp or as a thumping/grinding noise coming from the A/C compressor at vehicle start-up. Cause This condition may be caused by the A/C compressor trying to move liquid refrigerant through the system. Correction - A revised PCM calibration has been released to address this condition. Reprogram the PCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. - When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. - When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. - During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information Note *Please use Failure Code 93 for any warranty claims submitted using this bulletin. For vehicles repaired under warranty, use the table above. Page 8325 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 5622 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 15864 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 1852 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 20052 Radio Front Side Door Speaker Replacement Radio Front Side Door Speaker Replacement Page 3100 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 7917 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 4690 28. Connect the oil pressure sensor electrical connector (2). 29. Install the engine harness clamp (1) to the bracket. 30. Connect the following electrical connectors: * The EVAP canister purge solenoid valve (1) * The MAP sensor Page 13752 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 2728 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 19867 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Page 11050 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 10626 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 22239 Page 16099 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 6094 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 19011 Seat Belt Buckle: Diagrams Seat Belt Connector End Views Seat Belt Buckle - Driver Seat Belt Buckle - Passenger X1 (10 Series) Seat Belt Buckle - Passenger X2 (AL0) 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Page 3561 Spark Plug: Application and ID Spark Plug Type................................................................................................................................... ................GM P/N 126078234 AC Delco P/N 41-993 Page 7801 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 15441 Parking Brake Actuator: Service and Repair Parking Brake Actuator Replacement (JH6, JH7) Parking Brake Actuator Replacement (JH6, JH7) Page 6841 Accelerator Pedal Position Sensor: Service and Repair Accelerator Pedal Position Sensor Replacement Removal Procedure Notice: Handle the electronic throttle control components carefully. Use cleanliness in order to prevent damage. Do not drop the electronic throttle control components. Do not roughly handle the electronic throttle control components. Do not immerse the electronic throttle control components in cleaning solvents of any type. 1. Remove the knee bolster. 2. Push down the small tab and disconnect the accelerator pedal position (APP) sensor electrical connector (1). 3. Remove the accelerator pedal bolts. 4. Remove the accelerator pedal. Page 8317 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 129 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 21794 Page 1801 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 11161 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 21865 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 8450 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 3957 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 5920 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 8950 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 534 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 18238 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Page 9215 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 13617 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 24175 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 6676 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 16017 Page 12100 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 2908 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10608 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 20210 Parking Assist Control Module: Diagrams Object Detection Connector End Views Rear Object Sensor Control Module X1 Rear Object Sensor Control Module X2 Page 8124 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 16746 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 1644 Solar Sensor: Service and Repair Sun Load Sensor Replacement Page 13277 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 13474 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Page 8660 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Lighting - Turn Signals Have Increased Flash Rate Body Control Module: All Technical Service Bulletins Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 22274 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Page 7141 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 15761 11. Remove the positive battery cable terminal from the mega fuse stud. 12. Remove the positive battery cable channel from the studs. 13. Remove the positive battery cable from the vehicle. Installation Procedure 1. Install the positive battery cable to the vehicle. 2. Install the positive battery cable terminal to the mega fuse stud. Page 23889 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 1872 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 4968 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 16422 Multiple Junction Connector: Diagrams X300 - X399 X300 Inline Harness Connector End Views X300 Chassis Harness to Engine Harness (Gas) X303 Inline Harness Connector End Views X303 Body Harness to Driver Seat Harness (AN3) Page 12101 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 22946 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. SRS - Air Bag Lamp ON/DTC B0081 Set Seat Occupant Sensor: Customer Interest SRS - Air Bag Lamp ON/DTC B0081 Set Bulletin No.: 07-09-41-002 Date: January 29, 2007 TECHNICAL Subject: Air Bag Light On, DTC B0081 Set (Clear DTC Using Specific Procedure) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0081 with symptom code OF, 3A, 39 or 71 set. Correction The Sensing and Diagnostic Module (SDM) should NOT be replaced when DTC B0081 sets. The SDM sets DTC B0081 only to report that there is no communication with the Passenger Presence System (PPS) module or that the PPS module has reported a fault. It is important that when the B0081 fault is reported by the SDM, the DTCs from the PPS be retrieved and addressed first per the procedure below. After the PPS module DTCs have been addressed, turn the ignition off, open the driver's door, and wait 40 seconds for the PPS module to go to sleep. When DTC B0081 71 sets, inspect wiring and connections for a possible loss of communication between the SDM and PPS module. Inspect front passenger seat connector to the PPS module and seat connector to the seat harness. Do not replace the SDM module for a DTC B0081 71 condition. The SDM will set B0081 3A indicating that a wrong PPS module has been installed on the vehicle. Verify the condition before replacing the known wrong PPS module with a correct one. Use service information to reprogram and set up a new PPS module. The SDM will set B0081 OF and B0081 39 indicating that the PPS module has reported a fault to the SDM. Retrieve the DTCs from the PPS module and address those first. The PPS may continue to send it has a fault to the SDM for the above conditions, though there are no active faults reported by the PPS, until the steps in the note below are taken. DTC B0081 will not clear until the low speed bus goes to sleep. To clear DTC B0081 turn the Ignition off, open the driver's door and wait 40 seconds for the PPS to go to sleep. Turn the ignition to run and retrieve vehicle DTCs. If all the codes have been cleared from the PPS, DTC B0081 in the SDM will not be active and only be in history. Warranty Information For vehicles repaired under warranty, use the table. Page 5983 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 8886 Page 13628 Shift Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 6L50/6L80/6L90 - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Page 12406 Transmission Speed Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Input and Output Speed Sensor Replacement Page 13747 Page 794 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 6884 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 11086 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 6588 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Locations High Beam Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 17585 Alignment: Description and Operation Toe Description Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Steering/Suspension - Ball Joint Availability Control Arm: Technical Service Bulletins Steering/Suspension - Ball Joint Availability INFORMATION Bulletin No.: 07-03-08-009B Date: December 07, 2009 Subject: Two New Service Ball Joint Kits Available for Aluminum and Cast Iron Lower Control Arms - Kits NOT Interchangeable Models: 2007-2010 Cadillac Escalade, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Tahoe (1500 Series) 2007-2010 GMC Sierra, Yukon (1500 Series) Supercede: This bulletin is being revised to add the Silverado and Sierra models and update service information. Please discard Corporate Bulletin Number 07-03-08-009A (Section 03 Suspension). For the 2007-2010 model years, 1500 series light duty utility vehicles were built concurrently with either aluminum or cast iron front lower control arms. Each type of lower control arm requires a unique ball stud service part. Important Complete lower control arms should not be replaced for lower ball joint failures. All lower ball joints are now serviceable on aluminum and cast iron control arms for 1500 series pickup and utility models. The kit for cast iron control arms lower ball joints is P/N 19209396 and the aluminum lower ball joint kit is P/N 19256481. These kits are NOT interchangeable. There are new special tools that are released to service the lower ball joints on-vehicle (J-41805 and CH-49240). For the new lower ball joint service procedures, refer to Lower Control Arm Ball Joint Replacement in SI. Parts Information Disclaimer Page 805 Disclaimer Page 5304 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 9838 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 6863 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 1051 5. Disengage the retainer tabs securing the ECM to the bracket. 6. Remove the ECM. Installation Procedure 1. Install the bottom ECM tabs into the bracket. 2. Push the ECM in securing the ECM to the bracket. Drivetrain and Front Suspension Frame Front Crossmember Replacement (2WD 2500 HD, 3500) Cross-Member: Service and Repair Drivetrain and Front Suspension Frame Front Crossmember Replacement (2WD 2500 HD, 3500) Drivetrain and Front Suspension Frame Front Crossmember Replacement (2WD 2500 HD, 3500) Page 4105 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 24689 View of the connector when released from the component. View of another type of Micro 64 connector. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 13120 10. Using J 28458, release the pass-through electrical connector from the transmission case. 1. Use the small end of the J 28458 over the top of the connector. 2. Twist in order to release the four tabs retaining the connector. 3. Pull the harness connector down through the transmission case. 11. Remove the TCC solenoid (with O-ring seal) and wiring harness. 12. Inspect the TCC solenoid and wiring harness for the following defects: * Damage * Cracked connectors * Exposed wires * Loose pins Installation Procedure Page 9842 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 6360 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 2100 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 10785 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 5568 6. Install the flex coupling (1). Expand the sleeves of the flex coupler, if necessary, to properly fit over each pipe end. The centerline of the installed flex coupling should run parallel to the straight section of pipe (no bends in the coupling) for optimum performance. 7. Install the U-bolt clamps (2) on each sleeve end of the flex coupling. Tighten Tighten the U-bolt clamps to 30 Nm (22 lb ft). 8. Lower the vehicle. 9. Verify that the condition has been fixed. 1999-2000 4WD Models Built Prior to 1/20/2000 and All 2000-2011 2WD and 4WD Models Built After 1/2000 (With Regular Cab Short Bed ) Note This procedure uses a locally obtained 76 mm (3 in) flex coupling. Most larger exhaust shops will have these available. The kit listed below (P/N 15076990) is too long to use on regular cab short bed vehicles. Do not order the parts listed below. These models require the installation of a flex coupling. The flex coupling has adapter sleeves for the installation of U-bolt clamps. This procedure uses the U-bolt clamps, but the preferred installation method is to weld the flex coupler to the exhaust pipe. 1. Raise the vehicle. 2. Locate the first available straight section of pipe rearward of the mid-joint flange and forward of the muffler assembly. 3. Measure approximately 76 mm (3 in) on the straight pipe and mark. 4. Using a suitable cutting tool, cut out the marked section of the pipe and remove. 5. Remove any burrs, if necessary, before installing the flex coupler pipe. 6. Install the flex coupling, follow the manufacturer's installation instructions (1). Expand the sleeves of the flex coupler, if necessary, to properly fit over each pipe end. The centerline of the installed flex coupling should run parallel to the straight section of pipe (no bends in the coupling) for optimum performance. 7. Lower the vehicle. 8. Verify that the condition has been fixed. 1999-2000 2WD Models Built Prior to 1/2000 These models will require the installation of a flex coupler, two Y-pipe support brace rods w/integral U-bolt clamp assemblies on the LH and RH sides of the transmission rear mount and new transmission mount studs and nuts. The Y-pipe support braces are used in combination with the flex coupler to reduce exhaust moan. 1. Install the flex coupler using steps 1-7 in the first procedure(s). 2. Support the transmission with a suitable adjustable jack stand. 3. Remove the two bolts and nuts from the transmission rear mount. 4. Position the transmission rear mount and install two new studs to the mount. 5. Install the new studs supplied with the kit to the transmission mount. Page 13398 Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Page 11651 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 2952 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of A/C - Control Module A/C Indicator Blinking Control Module HVAC: All Technical Service Bulletins A/C - Control Module A/C Indicator Blinking Bulletin No.: 07-01-38-006 Date: August 20, 2007 INFORMATION Subject: Information For Vehicles with HVAC Control Module A/C Indicator Blinking Due to Low Battery State of Charge Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Manual Temperature Control HVAC System (RPO CJ3) An Air Condition (A/C) button on the Heating, Ventilation and Air Conditioning (HVAC) control module may blink when the A/C system is activated. The blinking indicator will turn to a solid light after cycling the A/C button or ignition key. This condition may be caused by a low battery state of charge on a PREVIOUS ignition key cycle. This condition may be due to situations were an unsold vehicle is parked for long periods of time as part of a dealership's unsold inventory. The A/C indicator begins to flash if the battery voltage falls below 9.5 volts. The low voltage condition may occur during an engine crank or if the vehicle is parked and a normal battery state of charge is not maintained. If the A/C indicator continues to blink, use the Tech 2(R) to help determine the cause. Connect the Tech 2 and build the vehicle. Select Powertrain. Select Engine Control Module (ECM). Select Data Display. Select Cooling/HVAC data. Make sure that there has been an A/C request signal. History should indicate any causes. If necessary, refer to SI for further information on HVAC system diagnostic procedures. Page 1783 Page 11182 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 16906 Fuse: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 9333 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 9145 Page 12521 Page 12446 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 23595 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 20526 Page 8407 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4517 1. Install a NEW rocker arm cover gasket to the cover. 2. Install NEW rocker arm cover bolt grommets to the cover, if necessary. 3. Install the rocker arm cover. Notice: Refer to Fastener Notice. 4. Install the rocker arm cover bolts. Tighten the bolts to 12 N.m (106 lb in). 5. Install the PCV valve hose to the valve cover and rocker cover. 6. Connect the power brake booster vacuum hose to the vacuum fitting. Page 11260 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6940 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 2925 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 12031 Pressure Regulating Solenoid: Service and Repair Control and Shift Solenoids Replacement Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 19059 Disclaimer Page 22475 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 6480 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 10986 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 4802 Fuel Pressure Release: Service and Repair Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (With CH 48027) Special Tools CH-48027 Digital Pressure Gage Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to Electrical Center Identification Views. 2. Remove the engine cover, if required. 3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 4. Remove the fuel rail service port cap. Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 5. Wrap a shop towel around the fuel rail service port. 6. Connect the CH-48027-3 (4) to the fuel rail service port. 7. Connect the CH-48027-2 (2) to the CH-48027-3 (4). 8. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 9. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 10. Close the valve on the CH-48027-2 (2). 11. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections Page 21873 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6489 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 11980 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 9261 Page 7035 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 9763 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 11191 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 405 Trailer Brake Controller Module (TBCM) Page 12386 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Page 11642 Page 7027 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 21921 Memory Seat Module X4 (AN3) Page 1499 Power Seat Switch: Diagrams Power Seat Connector End Views Seat Adjuster Switch - Driver (AG1 -AN3) Seat Adjuster Switch - Driver (AN3) Page 2001 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (7) from the camshaft position (CMP) sensor wiring harness jumper. 2. Remove the water pump. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor and wiring harness jumper from the engine front cover. 5. Disconnect the CMP sensor wiring harness jumper from the CMP sensor. 6. Remove the CMP sensor from the wiring harness jumper. Installation Procedure Page 10227 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Locations Dimmer Switch: Locations Lighting Systems Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 6355 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 24659 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 11020 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 5026 View of the connector when released from the component. View of another type of Micro 64 connector. Page 970 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Instruments/Audio - No Speaker Audio/Warning Chimes Audible Warning Device: Customer Interest Instruments/Audio - No Speaker Audio/Warning Chimes Bulletin No.: 07-08-44-008 Date: April 18, 2007 TECHNICAL Subject: No Audio/No Sound Heard from Radio Speakers, Turn Signals, Hazard Signals and No Warning Chimes When a Door or Liftgate is Opened (Inspect/Seat C2 Audio Amplifier Connector) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Speakers, Premium Audio w/Amplifier or Rear Stereo Audio (RPOs UQA, UQS or UK6) Condition Some customers may comment on one or all of the following conditions related to no audio/no sound: No sound from one or more of the radio speakers. No blinking sound heard form the turn signals or hazard signals when on. No audio warning chimes heard when a door or liftgate is opened. Cause The C2 Audio Amplifier Connector may become unseated at the amplifier. Correction Inspect/Seat the C2 Audio Amplifier Connector (16-way, Black Connector). Remove the radio, amplifier, and SIR fuses located in the Underhood Bussed Electrical Center (BEC). Gain access to the radio speaker amplifier. Refer to Radio Speaker Amplifier Replacement in SI. Page 19222 Seat Position Sensor: Diagrams SIR Connector End Views Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) Page 21510 Body Lock Pillar Trim Replacement (Extended Cab) Body Lock Pillar Trim Replacement (Extended Cab) Page 17987 13. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, lubricate the beads and reinflate. Overinflating may cause the bead to break and cause serious personal injury. Important: Allowable bead seating pressure is 345 kPa (50 psi) on Extended Mobility Tires. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Parts Information The product shown above is available from GM SPO. Disclaimer Page 10957 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 8259 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 15276 1. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the J 39544-KIT, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation. 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Brake Rotor Assembled Lateral Runout Measurement 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction. See: Brake Rotor Assembled Lateral Runout Correction 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Tools Required j 45101-100 Conical Brake Rotor Washers Page 20889 Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Technical Service Bulletin # 08-08-64-007 Date: 080513 Body - Outside Door Handle(s) Squeak When Operated TECHNICAL Bulletin No.: 08-08-64-007 Date: May 13, 2008 Subject: Squeaky Outside Door Handle (Grease U-Channel of Handle) Models: 2007-2008 Cadillac Escalade, Escalade EXT, Escalade ESV 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Condition Some customers may comment on a squeak noise coming from the door handle as the handle is actuated. Cause This condition may be caused by the pin and the inside of pawl surface making contact with each other, resulting in a squeak noise. Correction DO NOT REPLACE THE DOOR HANDLE. 1. Remove the fasteners to the door handle, leaving the rod to the latch attached. 2. Apply a generous amount of dielectric silicone grease, P/N 12345579 (in Canada, 10953481), as shown in the graphics, into the U-channel of the Page 3433 1 - Door Frame 2 - Window Switch - Left Rear (ABV) 3 - Speaker - Left Rear Door 4 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 5 - Window Motor - Left Rear (ABV) Right Rear Door (Extended Cab) Page 11783 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 14923 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 17033 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 13268 Notice: Refer to Fastener Notice. 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 N.m (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure. Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 12879 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 3308 5. Position the wheel and tire so the valve stem is situated at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. 6. Position the wheel and tire so that the valve stem is situated again at the 2 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM replace the tire pressure sensor. 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Important: If bead seat corrosion has been identified as an air loss concern on the wheel being worked on, refer to GM Service Bulletin # 08-03-10-006 for additional information on correcting the leak. 9. Apply GM P/N 12345884 (in Canada, P/N 5728223) or equivalent to the tire bead and the wheel rim. Page 6706 Page 16058 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 17119 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 10972 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 6097 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 9021 Page 16169 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 6407 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 4997 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 17425 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 8495 4. Position the knock sensor heat shield to the engine block and install the bolt. Tighten the bolt to 10 N.m (89 lb in). 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. Page 17930 7. Remove the jounce bumper (5) from the top mount assembly (3). 8. Secure the jounce bumper upright in a bench vise. Only clamp the lower portion of the bumper to allow the upper portion of the ID to remain at rest. Note A standard drill bit will not cut the ID of the jounce bumper. The jounce bumper will comply and stretch around the bit, then return after the drill is removed. 9. Prepare a single flute countersink bit or a bladed cutting bit, or equivalent, in a die grinder, Dremmel Tool, or equivalent. Page 6557 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (3) up and over the knock sensor. 4. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 5. Lower the vehicle. Page 17502 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 11149 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 9701 Page 3432 1 - Window Switch - Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 3 - Door Latch Assembly - Right Rear 4 - Speaker - Right Rear Door 5 - Window Motor Right Rear (A31) Left Rear Door (Extended Cab) Page 5834 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 1611 5. Install the left center pillar garnish molding. 6. Install the left center assist handle. 7. Install the left windshield garnish molding. Page 17093 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 16014 Junction Block - Left I/P, Label Junction Block - Left I/P, Device Usage Right I/P Junction Block Page 4936 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 16730 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 5393 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 22436 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 11984 Page 8080 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Locations Auxiliary Battery Relay: Locations Auxiliary Battery Harness (TP2) 1 - Fuse Holder - Underhood 2 - Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 10774 Page 6478 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 3489 D Height Measurement Important: The left and right D height difference should be no more than 14 mm (0.55 in). Use the following procedure to measure the D height. 1. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. Measure between the axle bracket and jounce bumper mount bracket as shown in graphic. 5. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 6. Gently remove your hands and let the vehicle settle. 7. Repeat this operation 2 more times for a total of 3 times. 8. Re-measure the D height as in step 4. 9. The true D height is the average of the measurement from step 4 and step 8. The side to side difference in D height must not exceed 14 mm (0.55 in). 10. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Page 20923 Owner Letter Owner Letter July 2010 Dear GM Customer: As the owner of a 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, or Yukon XL vehicle, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles may have a peeling condition on the top surface of the front or rear chrome interior door handle(s) that could create a rough edge. A chrome plating irregularity combined with direct sunlight exposure may cause the plating to separate from the top surface of the handle. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners of 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles with additional protection for the front and rear chrome interior door handles. If this condition occurs on your 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, or Yukon XL within 10 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by July 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. Scott Lawson Director, Customer and Relationship Services Enclosure 09239 Page 16440 X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Page 21886 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Diagrams Power Mirror Switch: Diagrams Mirror Connector End Views Outside Rearview Mirror Switch (DL8/DPN) Page 17973 Tire Pressure Module: Service and Repair Control Module Setup Remote Control Door Lock Receiver (RCDLR) Setup After remote control door lock receiver assembly replacement, the following procedures must be performed in the order that they appear for the tire pressure monitor (TPM) System to function properly. The RCDLR also requires keyless entry transmitter programming after replacement. Refer to Transmitter Programming. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool select Vehicle Control System. 4. Select Module Setups. 5. Select Remote Control Door Lock Receiver. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle drivers door placard sticker. 9. Select the rear tire pressure as noted on the vehicle drivers door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After RCDLR assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the RCDLR memory. Refer to Tire Pressure Sensor Learn. Page 22400 Page 23435 Tire Pressure Sensor: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 15200 Page 2577 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 14216 9. Remove the hub from the axle housing. 10. Remove the rotor, if necessary. 11. Remove the oil seal from the wheel hub using a suitable seal removal tool. 12. Remove the inner hub bearing. 13. Remove the inner hub bearing cup using a brass drift and a hammer. 14. Remove the retaining ring from the wheel hub. Page 8017 Data Link Connector: Diagrams Data Communication Connector End Views Data Link Connector (DLC) Page 22393 Seat Heater: Specifications Fastener Tightening Specifications Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 5299 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 2896 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 986 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 10648 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip (1) from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Lighting - Dome/Reading Lamps Inoperative Dome Lamp Switch: All Technical Service Bulletins Lighting - Dome/Reading Lamps Inoperative TECHNICAL Bulletin No.: 08-08-42-004 Date: August 27, 2008 Subject: Overhead Dome and/or Reading Lamp Inoperative With Push Button Switch (Replace Switch(es)) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado (New Body Style), Suburban, Tahoe 2007-2009 GMC Sierra (New Body Style), Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Some customers may comment that the overhead dome lamp and/or reading lamp is inoperative with the push button switch(es), even though the lamp still operates when the doors are opened. Correction The dome and/or reading lamp switch is now available for service as a separate part. The lamp switch was formerly available as part of the entire dome lamp housing or the roof console assembly. DO NOT replace the entire overhead dome lamp assembly or roof console if the lamp switch is required. Replace the lamp switch(es) using the steps below. 1. Remove the lamp lens by using a plastic flat-bladed tool to pry down on the right side of the lamp lens. 2. Remove the push button(s) (1) from the inoperative lamp switch(es). 3. Remove the dome lamp housing and/or roof console assembly. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 4. Slide the lamp switch(es) (1) away from the three electrical contact tabs (2) located on the back of the housing. 5. Remove the old switch(es) from the back side of the housing. 6. Install the new switch(es) through the back side of the housing. Page 6045 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 2204 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 7793 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 19851 Navigation Software Update Procedure: Use the following procedure to update the Navigation Radio software using the Nav Software Update Disc P/N 25956121 (software version 0B92): This software update can only be used to update the navigation radios specified in this bulletin. DO NOT use this software to update any other vehicle's navigation radio. The Map DVD will be needed to verify the system operation after the software update has been performed. Use the vehicle's existing map DVD. It is recommended to wear latex gloves while performing the software update, to avoid fingerprints on the product and discs. DO NOT stop the engine until all tasks are completed. The software update MUST be performed with the engine RUNNING and the gear position in PARK. If the vehicle is turned off prior to the software update being completed, the process may not work again and a new Navigation Radio may be required. The software update requires using the map DVD slot. The update will not work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Start the engine, with the gear shifter in PARK - wait until the audio or caution screen is displayed after the opening screen. Press the "NAV" hard key. Press "OK" soft key. Press the "MENU" hard key. Press the "NAV" soft key. Press the "MAP DATABASE INFORMATION" soft key. Press the "CHANGE" soft key. The navigation radio automatically ejects the map DVD. Remove the ejected disc. Load the update disc into the slot located behind the display screen by inserting it partially until the system pulls it in. DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. The screen "PREPARING TO LOAD SYSTEM SOFTWARE" will be displayed while the update is loading. The update should take approximately 4 Page 8355 Information Bus: Electrical Diagrams Data Communication Schematics Low Speed Bus - 1 of 3 Page 20738 1. Install the door upper striker (4). 2. Install the spacer, if equipped. 3. Install the door upper striker bolt (3). 4. If the striker backing plate has moved, rotate the lower striker bolt until the upper threaded hole is properly aligned. Notice: Refer to Fastener Notice. 5. Tighten the upper striker bolts. Tighten the door upper striker bolts to 24 N.m (18 lb ft). 6. Install the upper trim door upper striker cover. Ensure that the retainer clips were Not damaged when removed. Push upward into locator holes. Page 1243 Tire Pressure Module: Service and Repair Control Module Setup Remote Control Door Lock Receiver (RCDLR) Setup After remote control door lock receiver assembly replacement, the following procedures must be performed in the order that they appear for the tire pressure monitor (TPM) System to function properly. The RCDLR also requires keyless entry transmitter programming after replacement. Refer to Transmitter Programming. Tire Type/Pressure Selection Since there are different tire types and pressure combinations for different vehicles, it is necessary to select the correct tire type and tire pressures for the vehicle being serviced. 1. Install a scan tool. 2. Turn ON the ignition, with the engine OFF. 3. With the scan tool select Vehicle Control System. 4. Select Module Setups. 5. Select Remote Control Door Lock Receiver. 6. Select Tire Type/Pressure Selection. 7. Select P-Metric Standard. 8. Select the front tire pressure as noted on the vehicle drivers door placard sticker. 9. Select the rear tire pressure as noted on the vehicle drivers door placard sticker. 10. Verify the selections made are correct and press the enter key. The scan tool will flash Procedure in Progress, then display Procedure Complete. 11. Press the exit key to escape. Tire Pressure Sensor Learn After RCDLR assembly replacement, each of the tire pressure sensors unique identification codes must be learned into the RCDLR memory. Refer to Tire Pressure Sensor Learn. Page 567 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 985 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 3528 4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 5. Install the air cleaner outlet resonator to the MAT/IAT sensor. 6. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). Page 7013 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 10980 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 6797 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 24187 View of the connector when released from the component. View of another type of Micro 64 connector. Page 21469 Passenger Assist Handle: Service and Repair Roof Rail Rear Assist Handle Replacement Roof Rail Rear Assist Handle Replacement Page 9973 15. For vehicles equipped with 4WD perform the following steps, remove the left front CPA retainer. 16. Disconnect the engine wiring harness electrical connector (7) from the left front HO2S electrical connector (8). 17. Remove the left front HO2S electrical connector clip from the fuel line clip (2). 18. Remove the catalytic converter to muffler nuts. 4L60-E/4L65-E/4L70-E - Automatic Transmission Clutch Control Solenoid Valve: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 429 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 15758 Positive: Service and Repair Battery Positive Cable Replacement Battery Positive Cable Replacement (4.3L) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the under hood junction block cover. 3. Lift the junction block retainers from the locked position (3) and rotate the retainers to the open position (1). 4. Remove the junction block. Page 6158 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 16923 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23582 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 12088 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Page 11359 Vehicle Zoning Strategy Truck Zoning Page 15852 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Body - Headliner Wet/Water Leak Into Cab Past Sunroof Sunroof / Moonroof Weatherstrip: All Technical Service Bulletins Body - Headliner Wet/Water Leak Into Cab Past Sunroof TECHNICAL Bulletin No.: 08-08-67-006B Date: April 11, 2011 Subject: Headliner Wet, Water Leak into Cab, Water Leak Past Sunroof Glass Weatherstrip/Seal (Inspect Sunroof Weatherstrip/Seal and Replace if Necessary) Models: 2007-2012 Chevrolet Silverado Crew Cab Models 2007-2012 GMC Sierra Crew Cab Models with Sunroof (RPO CF5) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-67-006A (Section 08 - Body and Accessories). Condition Some customers may comment on the headliner being wet or water leaking into the cab. Cause The sunroof glass weatherstrip/seal may not be completely water tight. The weatherstrip/seal may not be properly secured to the glass panel. Correction Important DO NOT replace the sunroof glass panel. Technicians are to inspect the glass panel seal appearance at the corners and around the glass panel. If the weatherstrip/seal looks depressed or concave in the middle, as shown above, replace the seal. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 5321 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 18493 3. Install the discharge hose to the condenser using new sealing washers. Notice: Refer to Fastener Notice. 4. Install the discharge hose nut to the condenser. Tighten the nut to 16 N.m (12 lb ft). 5. Install the upper air baffle. 6. Install the discharge hose (1) to the A/C compressor using new sealing washers. 7. Install the discharge hose mounting bolt. Tighten the bolt to 16 N.m (12 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using the J 39400-A. Page 14126 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X115 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X115 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 6. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Hybrid Models Chafed Wiring Harness Locations/Inspections Hybrid Models (HP2) Chafed Wiring Harness Locations and Inspection of Engine Harness Connector X150 for Backed Out Terminals and Poor Connections at Ground Locations G102 and G300 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X150 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X150 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the connector repair. 5. Inspect for a misrouted/chafed harness rubbing on the cooling fins of the Transmission Auxiliary Fluid Pump Control Module as shown. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Inspect for a chafed harness caused by a mispositioned retaining clip as shown. The chafing condition usually occurs when the tab of the clip is aligned with a slot in the conduit. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 7. Locate ground connections G102 and G300. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > G102 and G300 in SI. 8. Inspect G102 and G300 for a clean and tight connection. Undercoating has been found between the eyelet and the frame resulting in a poor connection. Page 8578 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 10762 and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 6. Connect a test lamp between the relay coil B+ and the relay coil control circuit. 7. Ignition ON, command the powertrain relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the relay coil control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the relay coil control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 8. Connect a 20A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 9. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 10. If all circuits test normal, test or replace the relay. Component Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Test for 65-110 ohms of resistance between terminals 85 and 86 of the relay. ‹› If the resistance is not within the specified range, replace the relay. 3. Test for infinite resistance between following terminals: * Terminal 30 and 86 * Terminal 30 and 87 * Terminal 30 and 85 * Terminal 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 20A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm of resistance between terminals 30 and 87. ‹› If greater than the specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Relay Replacement (Within an Electrical Center) Relay Replacement (Attached to Wire Harness) * Underhood Electrical Center or Junction Block Replacement * Refer to Programming and Relearning for setup and programming. See: Testing and Inspection/Programming and Relearning Page 8876 Page 18590 - Proof of ownership at time of repair. - Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair. If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership. Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer. Disclaimer Page 14707 Page 21944 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 460 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 5369 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 9637 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 10481 Fuel Injector 1 Page 41 Disclaimer Page 16711 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Diagrams Power Steering Fluid Reservoir: Diagrams Power Steering Pump Disassembled View Power Steering Pump Disassembled View 1 - Power Steering Fluid Reservoir 2 - Power Steering Fluid Reservoir Cap 3 - Power Steering Fluid Reservoir Stud 4 - Power Steering Fluid Reservoir Stud 5 - Power Steering Pump Fitting 6 Power Steering Pump Fitting Seal 7 - Power Steering Pump Flow Control Valve 8 - Power Steering Pump Flow Control Valve Spring 9 - Power Steering Pump Housing Seal 10 - Power Steering Pump Housing Seals 11 - Power Steering Fluid Reservoir Seal 12 - Power Steering Pump 13 Power Steering Pump Shaft Seal 14 - Power Steering Fluid Reservoir Magnet Page 7086 Page 1894 Page 679 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 23413 Customer TPMS Information Page 5530 5. Install the spark plugs. 6. Position the exhaust manifold heat shield to the manifold and install the bolts. Tighten the bolts to 9 N.m (80 lb in). 7. Raise and support the vehicle. 8. Install the catalytic converter to exhaust manifold nuts (1). Tighten the nuts to 50 N.m (37 lb ft). 9. Lower the vehicle. Page 2264 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 5949 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12221 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 6228 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6649 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 17075 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 9826 5. Connect the VSS electrical connector (2). 6. Lower the vehicle. 7. Refill the fluid as required. Page 13536 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 13956 Disclaimer Page 17961 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 22551 Page 17099 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 2018 Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 7632 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 9664 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 4124 Junction Block - Left I/P X1 (Pin M2 To P5) Junction Block - Left I/P X2 Page 12153 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 11724 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14330 3. Install the axle shaft seal using the J 21128. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. Page 12679 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 6470 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 8546 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 3042 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 Removal Procedure Notice: Refer to Heated Oxygen and Oxygen Sensor Notice. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If vehicle is a 2-wheel drive (2WD) perform the following steps, otherwise proceed to step 5. 3. Disconnect the connector position assurance (CPA) retainer. 4. Disconnect the HO2S pigtail electrical connector (7) from the engine wiring harness electrical connector (6). 5. If vehicle is a 4-wheel drive (4WD) perform the following steps, disconnect the CPA retainer. 6. Disconnect the engine wiring harness electrical connector (7) from the HO2S pigtail electrical connector (8). Page 1465 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 3797 Engine Oil: Fluid Type Specifications ENGINE OIL TYPE LOOK FOR TWO THINGS: 1.Your vehicle's engine requires oil meeting GM Standard GM6094M. 2.SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 20W-50. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). You should look for this information on the oil container, and use only those oils that are identified as meeting GM Standard GM6094M and have the starburst symbol on the front of the oil container. NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES Do not add anything to your oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all you will need for good performance and engine protection. Page 7281 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 14251 Note: Drive the outer bearing cup into the wheel hub until it is just past the retaining ring groove. Do not bottom out the bearing assembly in the bore. 7. Using the J 44419 installer (2) and the J 8092 handle (1), install the outer bearing cup into the rear axle hub. Note: Ensure that the retaining ring is fully and evenly seated in the groove. 8. Install the retaining ring into the groove. Page 17340 Inline Harness Connector End Views X103 Instrument Panel Harness to Forward Lamp Harness X106 Inline Harness Connector End Views X106 Forward Lamp Harness to Right Front Headlamp Harness Page 14925 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 11776 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 10898 Page 1609 Cabin Temperature Sensor / Switch: Diagrams HVAC Connector End Views Inside Air Temperature Sensor - Front Page 17085 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 7533 * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Procedures Wiper Blade: Procedures Blade Element Cleaning 1. Lift the wiper blade assemblies off of the windshield glass. 2. Clean the wiper blade element with a clean cloth saturated with full strength washer solution. 3. Rinse the wiper blade assemblies with water. 4. Place the wiper blade assemblies back onto the windshield glass. Page 23932 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 20728 Front Door Panel: Service and Repair Upper Extension Trim Panel Replacement Upper Extension Trim Panel Replacement Page 5451 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 3871 Page 13837 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 9553 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. Notice: Do not rotate or pry on the MAP sensor when removing. Damage to the MAP sensor or the intake manifold may result. 2. Remove the MAP sensor bolt (1). 3. Using a slight rocking motion while pulling straight up, remove the MAP sensor (2) from the upper intake manifold. 4. Inspect the MAP sensor seal for damage, replace the seal if necessary. Installation Procedure Page 2966 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 7580 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 10434 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10401 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 16529 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 6618 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 9369 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Testing and Inspection/Diagnostic Trouble Code Descriptions 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Testing and Inspection/Diagnostic Trouble Code Descriptions 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 11183 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 6860 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 12894 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 438 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 18986 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1065 Page 21624 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 13892 Transmission Mode Switch: Locations Shift Lock Control Component Views Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Entertainment System - DVD Monitor Display Inoperative Television / Monitor: Customer Interest Entertainment System - DVD Monitor Display Inoperative Bulletin No.: 07-08-44-016A Date: August 28, 2007 TECHNICAL Subject: GM Accessories Headrest DVD System Display Monitor Inoperative (Install Cable Connector Clamps) Models Supercede: This bulletin is being revised to update the models affected list. Please discard Corporate Bulletin Number 07-08-44-016 (Section 08 - Body & Accessories). Condition Some customers may comment on an inoperative display monitor or monitors in the GM Accessories Headrest DVD System. Cause This condition may be caused by a loose connection at the display monitor cable connectors. These connectors are located at the lower rear part of both front seats. Two cables are routed to the display monitor in each seat. Correction A number of headrest monitors have been replaced under warranty and in many cases, no trouble was found by the supplier when these units were Page 11286 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Page 5934 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 2751 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 6950 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 2041 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 3202 Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (Extended Cab +ASF) Inflatable Restraint Vehicle Rollover Sensor (ASF) Page 10059 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 7182 Audio System - Static/Ignition Noise on AM Band Ground Strap: All Technical Service Bulletins Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Page 12270 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 3368 For vehicles repaired under warranty, use the table. Disclaimer Page 1659 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 11244 Vehicle Zoning Strategy Truck Zoning Page 17911 Suspension Strut / Shock Absorber: Service and Repair Rear Suspension Shock Absorber Shock Absorber Replacement Shock Absorber Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the rear axle. 3. Remove the upper shock absorber nut and the bolt. 4. Remove the lower shock absorber nut and the bolt. 5. Remove the shock absorber. Installation Procedure Page 22412 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 7440 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Page 23389 Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 15132 Electronic Brake Control Module (JL4) Page 16146 1 - G111 (XA7) 2 - G108 3 - G110 (XA7) 4 - Brake Booster Assembly 5 - Fuse Block - Underhood 6 - G104 (6A6) Below the I/P Page 17240 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 22295 Disclaimer Page 1793 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 14509 Disclaimer Page 9786 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 15877 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 8209 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 7247 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 17047 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 8328 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 2528 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 12115 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 6766 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 12876 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 17626 21. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 22. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 23. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 24. Install the connector to the sensor. Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Temperature Versus Resistance Page 16432 X319 Inline Harness Connector End Views X319 Body Harness to Console Harness (AZ3/D07 +UQ3) Page 15880 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 21612 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 16253 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 1413 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 14029 Page 7329 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 18914 Inflatable Restraint Sensing and Diagnostic Module (SDM) (Regular/Extended Cab -10 Series) Page 16069 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 7862 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 11963 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15791 9. Install the A/C compressor and condenser hose bracket bolt (2). Tighten the bolt to 25 N.m (18 lb ft). 10. Instal the engine wiring harness clip (1) to the A/C compressor/condenser hose bracket. 11. Install the drive belt. 12. Install the air cleaner outlet resonator. 13. Connect the negative battery cable. Page 17203 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 21186 Page 17361 X211 Instrument Panel Harness (Y91) Or I/P Extension Harness (-Y91) To Console Harness (Y91/UQA/D07) (Pin A1 To C6) Page 12243 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 7261 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 24426 Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement (Power) Locations Sunroof / Moonroof Module: Locations Sunroof Component Views Sunroof Module 1 - Sunroof Module 2 - Left Outer Frame Panel Page 16037 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 14522 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5379 Page 21572 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 4828 Spark Plug: Application and ID Spark Plug Type................................................................................................................................... ................GM P/N 126078234 AC Delco P/N 41-993 Page 16222 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 3858 Fuse Block - I/P, Device Usage Page 8347 Body Control Module (BCM) X4 Page 17789 8. Install the following parts onto the steering column shaft assembly: 1. Lubricate the steering shaft upper bearing inner race (1) with GM P/N 12345718 (Canadian P/N 10953516). 2. The steering shaft upper bearing inner race (1) 3. The steering shaft upper bearing inner race seat (2) 4. The steering shaft upper bearing spring (3) 5. Lubricate the turn signal switch cancel cam (4) with GM P/N 12377900 (Canadian P/N 10953529). 6. The turn signal switch cancel cam (4) 7. The turn signal switch cancel cam position plate (5) 9. Install the new steering shaft lock plate retaining ring onto the steering shaft using compressor J 23653-SIR and adapter J 42137. 10. Install the automatic transmission control assembly. 11. Install the tilt spring. 12. Install the ignition lock cylinder case. 13. Install the turn signal multifunction switch. 14. Install the inflatable restraint steering wheel module coil. 15. Install the steering column. Page 22933 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 20952 Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. 2. Allow the latch to completely thaw and apply compressed air for two seconds to the latch to force out any moisture. Refer to the above illustration (slashed area) for the location. Spray GM Super Lube(R) on BOTH sides of the latch detent lever for approximately two to three seconds. Refer to the above illustration (slashed area) for the lube location. Repeat for all door latches. Operate the door latch several times to spread the lubricant on all surfaces. Parts Information Warranty Information Allison - Automatic Transmission Transmission Mode Switch: Diagrams Allison - Automatic Transmission Automatic Transmission Internal Connector End Views Transmission Internal Mode Switch Page 10249 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 5165 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 7935 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 2241 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 7929 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 4208 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 22948 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 7346 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 2192 Page 15552 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 572 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 9458 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 11673 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 17741 * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flushed rotor flange cuff (6) * An alignment mark (5) for installation 6. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing into the adapter and bearing assembly * A view of the inside of the connector Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 7. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 8. Install the connector to the sensor. 9. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 10. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing into the adapter and bearing assembly Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 11. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 12. Install the connector to the sensor. Page 19115 Impact Sensor: Diagrams SIR Connector End Views Inflatable Restraint Front Sensor - Left (10 Series) Inflatable Restraint Front Sensor - Right (10 Series) Inflatable Restraint Front Sensor (-10 Series) Page 10494 18. Open the valve (2) on the tank (3). 19. Open the valve (4) on the J 44466-10 to pressurize the fuel system. Then close valve (4) before firing injectors. Important: The minimum pressure required on the gage (6) is 150 psi. If 150 psi is not obtained, the tank (3) must be refilled prior to performing this procedure. 20. Fire one injector using the J 39021. Observe a pressure drop on the gage (6) and verify the injector/poppet valve operation. An injector/poppet that is stuck and not operational will have no pressure drop on the gage. If an injector remains stuck, repeat the procedure multiple times (as required) until the injector is operational. 21. Repeat steps 19 and 20 for each individual injector to verify that all injector/poppet valve assemblies are unstuck and functional. 22. Shut off the pressure valve (2) on the tank (3) of the J 41413. 23. Bleed off the pressure at the J 44466-10. 24. Install the PCV fresh air tube to the air inlet duct. 25. Disconnect and remove the J 44466-10 (1) from the J 44466-12 (3) and the J 41413. 26. Remove the J 39021-301, J 39021-210 and J 39021 from the metering body. 27. Install the vehicle electrical connector to the metering body. 28. Install brake booster vacuum hose and connector to the intake manifold. 29. Install ignition wires 1, 3, and 5 to the distributor cap. 30. Install the resonator and air intake duct to the throttle body and hand tighten wing nut. Page 11956 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 16091 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 21059 10. Remove the regulator (1) and cables (2) from the vehicle. Installation Procedure 1. Install the regulator (1) and cables (2) to vehicle. Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 21048 Tighten bolt to 11 N.m (97 lb in). 6. Install the rear sliding window lower garnish molding. 7. Inspect the rear sliding window for proper operation. Page 2669 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 21833 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 9144 Camshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 14105 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X115 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X115 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the repair. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 6. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Hybrid Models Chafed Wiring Harness Locations/Inspections Hybrid Models (HP2) Chafed Wiring Harness Locations and Inspection of Engine Harness Connector X150 for Backed Out Terminals and Poor Connections at Ground Locations G102 and G300 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Locate the X150 connector. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > X150 in SI. 4. Inspect the connector for the following conditions: - Backed out terminals - Bent pins - Corrosion - Poor terminal fit (use the correct test probe) ‹› If a condition is found, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. AND ‹› If corrosion is found, proceed to the section of the bulletin titled: Repairing Fretting Corrosion to complete the connector repair. 5. Inspect for a misrouted/chafed harness rubbing on the cooling fins of the Transmission Auxiliary Fluid Pump Control Module as shown. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Inspect for a chafed harness caused by a mispositioned retaining clip as shown. The chafing condition usually occurs when the tab of the clip is aligned with a slot in the conduit. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 7. Locate ground connections G102 and G300. Refer to Wiring Systems and Power Management > Component Locator > Master Electrical Component List > G102 and G300 in SI. 8. Inspect G102 and G300 for a clean and tight connection. Undercoating has been found between the eyelet and the frame resulting in a poor connection. Page 6406 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 4681 11. Disconnect the control port injector module (1). 12. Disconnect the following electrical connectors: * The EVAP canister purge solenoid valve (1) * The manifold absolute pressure (MAP) sensor 4L60-E/4L65-E/4L70-E - Automatic Transmission Control Module: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (TCM) 1 - Transmission Control Module (TCM) Page 8298 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 5826 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7554 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 23507 Brake Lamp Relay: Locations TRLR LT STOP/TURN PCB Relay Electrical Center Identification Views Fuse Block - Underhood, Label A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Sunroof Motor/Actuator Replacement (Extended Cab) Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement (Extended Cab) Sunroof Motor/Actuator Replacement (Extended Cab) Removal Procedure Important: The sunroof motor/actuator drive shaft turns in both directions and contains no limit switches. You may replace the sunroof motor/actuator with the window panel in any position. 1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Regular Cab) Headlining Trim Panel Replacement (Extended Cab) Headlining Trim Panel Replacement (Crew Cab). 2. Disconnect the electrical connector (1) from the motor/actuator. 3. Remove the screws (2) from the sunroof motor/actuator. 4. Pull straight down to disengage the drive gear from the cables housed within the sunroof cable drive tubes. 5. Remove the sunroof motor/actuator (3) from the sunroof module. Installation Procedure Page 2175 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Tank Pressure Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 9845 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 20560 Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Extension Replacement (Chevrolet) Front Bumper Impact Bar Extension Replacement (Chevrolet) Page 8915 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 3022 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 8577 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 6658 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23088 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 18109 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 6393 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 15402 Page 15020 Fluid Pressure Sensor/Switch: Diagrams Automatic Transmission Internal Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Front Door Opening Weatherstrip Replacement (Crew Cab) Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Crew Cab) Front Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the front door sill plate. Refer to Front Side Door Sill Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Plate Replacement (Extended Cab) . 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. Page 17856 Drivetrain and Front Suspension Frame Front Crossmember Replacement (4WD 2500 HD, 3500) Drivetrain and Front Suspension Frame Front Crossmember Replacement (4WD 2500 HD, 3500) Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 1555 1 - Wheel Speed Sensor (WSS) - Left Rear (JL4) 2 - Wheel Speed Sensor (WSS) - Right Rear (JL4) Page 9659 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Electrical - 'No Trailer Connected' Message On DIC Trailer Brake Control Module: Customer Interest Electrical - 'No Trailer Connected' Message On DIC TECHNICAL Bulletin No.: 09-05-22-004 Date: November 05, 2009 Subject: No "Trailer Connected" Message on Driver Information Center (DIC) at Startup When Trailer is Connected (Reprogram ITBCM) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Equipped with Integrated Trailer Brake (RPO JL1) Condition Some customers may comment that when they connect their trailer, with the engine off, and after they start the engine, the Trailer Connected message is not displayed on the DIC. With the engine running, if the trailer connector is cycled, the vehicle will detect the trailer and display Trailer Connected. This concern should only affect trailers equipped with trailer brakes on a single axle. Cause The trailer brake control system is only compatible with trailers equipped with electric trailer brakes. The system will not work or detect trailers equipped with any other types of brakes such as surge, air or electric-over-hydraulic trailer brake systems. When a trailer is connected, the Trailer Brake Control Module (TBCM) performs a test to determine if the trailer is equipped with electric trailer brakes. If the trailer wiring or electric trailer brake magnets have additional resistance (caused by poor connections, corrosion, improper splices, etc.), the TBCM may not be able to detect the trailer. Correction A revised calibration has been developed to address these issues. Reprogram the Integrated Trailer Brake Control Module (ITBCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Refer to Trailer Brake Control Module Programming and Setup in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Diagrams Outside Temperature Display Sensor: Diagrams Mirror Connector End Views Ambient Air Temperature Sensor (DF5) Service and Repair Pinion Bearing: Service and Repair Drive Pinion Bearings Replacement (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Tools Required * J 7818 Inner Bearing Race Installer, 9.5/9.5LD inch axle * J 8092 Driver Handle 3/4 in - 10 * J 8608 Rear Pinion Bearing Race Installer, 8.6 inch, 11.5 inch axle * J 8611-01 Rear Pinion Bearing Race Installer * J 8614-01 Flange and Pulley Holding Tool * J 22306 Pinion Cup Bearing Installer - Rear, 9.5/9.5LD inch axle * J 22388 Rear Axle Pinion Oil Seal Installer, 8.6 inch, 9.5/9.5LD inch axle * J 22912-B Split Plate Bearing Puller * J 24433 Pinion Cone and Side Bearing Installer, 8.6 inch axle * J 36614 Inner Pinion Bearing Installer, 9.5/9.5LD inch axle * J 44412 Pinion Bearing Installer, 11.5 inch axle * J 44414 Rear Axle Pinion Oil Seal Installer, 11.5 inch axle * J 44417 Rear Pinion Bearing Race Installer, 11.5 inch axle * J 45871 Pinion Bearing Remover * J 45870 Pinion Bearing Cup Installer, 8.6 inch axle Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the drive pinion from the axle. 4. For the 8.6 inch axle, install the J 45871 (1) around the pinion bearing and the J 22912-B (2) in the inverted position around the J 45871. 5. Press the bearing off of the pinion using the J 45871 and the J 22912-B. Page 22681 Note Ensure that the cross-car adhesive foam is positioned at a height just below the insulator push pin fastener locations so that once the fasteners are installed, the seal is compressed. - Across the inner rear body panel, matching the width of the insulator panel. - Downward from each end of the cross-car foam (left side (1) shown in the graphic above). The length should match the height of the insulator panel. - Partially around the two PRV's. Install the foam down the outboard side (1), underneath (2), partially back up the inboard side (3), then finish with a length extending further inboard (4) from the PRV. Important Ensure that any C-pillar wiring harnesses/connectors are routed forward of the insulator, and not trapped behind it. 4. Position the body rear panel insulator to the inner rear body panel and install the push pin retainers. Caution should be taken to not disturb the foam tape installed previously. Body - Outside Door Handle Pulls Out of Base Front Door Exterior Handle: All Technical Service Bulletins Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Warranty Information Page 13692 Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 18. Remove the range selector cable from the support. 19. Remove the cable grommet from the floor panel. 20. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. 2. Install the cable grommet to the floor panel. Page 14211 Tools Required * J 8092 Universal Driver Handle-3/4 in - 10 * J 21128 Axle Pinion Oil Seal Installer (8.6 inch and 9.5 inch LD Axles) * J 23690 Axle Shaft Bearing Installer (8.6 inch and 9.5 inch LD Axles) * J 2619-01 Slide Hammer * J 29709 Wheel Bearing Installer (9.5 inch Axle) * J 29712 Wheel Bearing Remover (9.5 inch Axle) * J 29713 Axle Seal Installer (9.5 inch Axle) * J 44685 Rear Axle Seal and Bearing Remover (8.6 inch and 9.5 inch LD Axles) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the rear axle housing cover. 4. Remove the axle shaft. 5. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (8.6 inch and 9.5 inch LD axles) (1) and the J 2619-01 (2). 6. Remove the axle shaft seal and the bearing from the axle housing using the J 29712 (9.5 inch axle). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (8.6 inch and 9.5 inch LD axles) (1) or the J 29709 (9.5 inch axle) (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Locations Cabin Temperature Sensor / Switch: Locations HVAC Component Views Front Headliner Components 1 - Inside Air Temperature Sensor - Front (CJ2) 2 - Cellular Microphone (UE1/U3U/UVB) 3 Courtesy/Reading Lamps - Rear (Extended Cab/Crew Cab) 4 - Sunroof Switch (CF5) 5 - Sunshade - Right (DH6) 6 - Garage Door Opener (UG1) 7 - Onstar Button Assembly 8 - Inside Rearview Mirror (ISRVM) 9 - Courtesy/Reading Lamps - Front 10 - Windshield 11 - Sunshade - Left (DH6) Page 15391 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the J 45405. 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. Page 5280 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 23905 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 2244 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 23810 1. Remove the instrument panel (I/P) knee bolster. Refer to Knee Bolster Replacement in SI. 2. Remove the park brake release handle. Refer to Park Brake Release Handle Assembly Replacement SI. 3. Locate the left bussed electrical center (LBEC), which is located on the left end of the instrument panel IP. 4. Locate the 40-way connector X1 that is attached to the back of the LBEC. 5. Disconnect the 40-way connector X1 from the LBEC. Page 445 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 22999 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 6286 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 7450 1. Install the air cleaner outlet resonator to the MAF/IAT sensor and throttle body. Notice: Refer to Fastener Notice. 2. Tighten the air cleaner outlet resonator clamp (2) at the throttle body. Tighten the clamp to 4 N.m (35 lb in). 3. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). 4. Connect the PCV hose (1) to the air cleaner outlet resonator. Audio System - Static/Ignition Noise on AM Band Ignition Cable: Customer Interest Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Specifications Water Pump: Specifications Water Pump Bolt ................................................................................................................................. .......................................................... 45 N.m 33 lb ft Page 8754 Body Control Module (BCM) X6 Page 9864 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 543 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 24416 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7982 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 17623 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Page 7207 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 10680 19. If equipped with 4WD perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service. 20. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. 21. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 22. Remove the fuel line bracket bolt (1). 23. Remove the fuel/EVAP line clip nut (2). 24. Remove the fuel/EVAP line clips from the frame and crossmember. 25. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure 1. If equipped with 4WD perform the following steps, position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Notice: Refer to Fastener Notice. Fuse Block - I/P, Top View Power Door Lock Relay: Locations Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Label Page 22223 Rear Seat Back Recliner Cover Replacement (Crew Cab with A68) Page 5242 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 12253 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 9913 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 7409 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 4642 2. Install the oil filter adapter. Tighten the adapter to 55 N.m (41 lb ft). 3. Install the oil filter. Tighten the filter to 30 N.m (22 lb ft). 4. Lower the vehicle. 5. Fill the engine with the proper quantity and quality of engine oil. Refer to Approximate Fluid Capacities. Page 7556 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 7829 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 18445 Discharge Air Temperature Sensor / Switch: Diagrams HVAC Connector End Views Air Temperature Sensor - Upper Left Air Temperature Sensor - Upper Right Air Temperature Sensor - Lower Left Page 17337 X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Page 4958 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 22247 1. Release the seat cushion cover J-retainer from the seat frame and roll the J-retainer/trim completely down. 2. Locate the slot on each side of the cushion pan frame by lifting the cushion/cover up and away from the lower edge of the frame to expose the slots (1). 3. Using a ruler and marker, measure and mark the cushion trim to match up with the slots on the cushion pan J-retainer attachment tab location. Repeat this process on the opposite end of cushion trim cover. Important Ensure that the J-retainer is fully unrolled, and that the holes are drilled through the lower edge of the J-retainer (1) and not through the U-channel (2) of the retainer. Page 1042 Page 2606 Air Flow Meter/Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 1970 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 14 Page 7591 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 9020 OnStar(R) - Language Change Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Page 11081 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7376 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8989 Engine Control Module: Connector Views Engine Control Module Connector End Views Engine Control Module X1 Page 22269 For vehicles repaired under warranty, use the table above. Disclaimer Page 17708 1. Install the power steering gear outlet pipe (1) to the steering gear (2). 2. Connect the power steering fluid cooler hose (3) and hose clamp to the steering gear (2). 3. Clean any excess fluid from the vehicle and remove the drain pans. 4. Fill and bleed the power steering system. Page 17392 X601 Inline Harness Connector End Views X601 Right Front Door Harness to Body Harness (ASF) Interior - Cleaning Interior Surfaces of Vehicle Seat Cover: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Page 20735 Front Door Striker: Service and Repair Door Striker Replacement (Extended Cab Lower) Door Striker Replacement (Extended Cab, Lower) Removal Procedure Important: If both of the door striker bolts are removed at the same time, the striker backing plate will fall into the body. This will result in additional time to perform the repair. 1. Remove the door lower striker bolts (1). 2. Remove the spacer, if equipped. 3. Remove the door lower striker (2). Installation Procedure Page 24037 Trailer Brake Control Panel Switch Page 3137 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 13889 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 2929 Page 10837 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Page 21826 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 9581 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Locations Power Seat Motor: Locations Power Seat Component Views Driver Seat 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (AN3) Diagrams Outside Temperature Display Sensor: Diagrams Mirror Connector End Views Ambient Air Temperature Sensor (DF5) Page 13076 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Specifications Spark Plug: Specifications Spark Plug Gap.................................................................................................................................... ...........................................................1.5 mm (0.06 in) Spark Plug Torque......................................... ................................................................................................................................................15 N.m (11 lb ft) Page 9138 Page 5098 Page 11926 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 15190 equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes 15. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. Page 8531 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Tank Unit: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 18108 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 10612 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 5067 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 6109 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5830 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 22958 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 17794 6. Remove the steering shaft coupling nut (1) and bolt (2) at the upper intermediate steering shaft. 7. Remove the steering shaft coupling from the vehicle. Installation Procedure Important: If a new steering shaft coupling is being installed then transfer the position of the alignment marks from the old component to the same locations on the new component. Failure to transfer the alignment marks may result in an off-center steering wheel after installation. 1. Install the steering shaft coupling to the vehicle. Notice: Refer to Fastener Notice. 2. Install the steering shaft coupling nut (1) and bolt (2) at the upper intermediate steering shaft. Tighten the nut and bolt to 50 N.m (37 lb ft). Page 8321 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 12686 View of the connector when released from the component. View of another type of Micro 64 connector. Allison - Automatic Transmission Transmission Speed Sensor: Service and Repair Allison - Automatic Transmission Speed Sensor Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Be sure the vehicle ignition is turned off. 2. Disconnect the external wiring harness from the speed sensor. 3. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). Installation Procedure A/T - Valve Body Reconditioning Info. Valve Body: All Technical Service Bulletins A/T - Valve Body Reconditioning Info. INFORMATION Bulletin No.: 08-07-30-006A Date: October 13, 2009 Subject: HYDRA-MATIC(R) 6L45 (MYA), 6L50 (MYB), 6L80 (MYC) and 6L90 (MYD), Rear Wheel Drive Automatic Transmission Control Valve Body Assembly Reconditioning Models: 2006-2009 Cadillac XLR 2006-2010 Cadillac STS 2007-2009 Cadillac SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2010 Cadillac CTS 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon Denali, Yukon Denali XL 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L45, 6L50, 6L80 or 6L90 HYDRA-MATIC(R) Rear Wheel Drive Automatic Transmission (RPOs MYA, MYB, MYC, MYD) Supercede: This bulletin is being revised to update model years and add 6L45 transmission (RPO MYA). Please discard Corporate Bulletin Number 08-07-30-006 (Section 07 Transmission/Transaxle). The information outlined in this bulletin is designed to provide easy to follow control valve body reconditioning instructions using the new illustrations to simplify reassembly of the 6L45, 6L50, 6L80 and/or 6L90 automatic transmission control valve body assembly. Caution Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result. Notice After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in order to dry any transmission components. Lint from the towels can cause component failure. Notice Do not reuse cleaning solvents. Previously used solvents may deposit sediment, which may damage the component. Inspection Procedure for Shift Concerns 1. Using the exploded view, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. IF VALVE BODY CLEANING IS NOT REQUIRED, DO NOT DISASSEMBLE THE BORES UNLESS IT IS NECESSARY TO VERIFY MOVEMENT. 2. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. 3. If a valve is restricted and cannot be corrected by cleaning the valve and bore, replace the valve body. Describe the restricted valve on the repair order. Disassembly/Reassembly for Cleaning Debris 1. If a valve is restricted by a metal burr from machining that bore, remove the valve and burr. Inspect the movement in the valve's normal position. If no other debris or restrictions are found, reassemble the valve body and install in the transmission. 2. If the valve body has been contaminated with debris from another transmission component failure, disassemble all bores for complete cleaning of all valve body components. Keeping individual bore parts separated will make reassembly easier. Use the following illustrations for positive identification and location of individual parts. 3. Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Page 2374 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 12176 Shift Solenoid: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Page 13777 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 22414 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 5936 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 104 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Page 7020 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Instrument Panel Electrical Center or Junction Block Replacement - Left Side Fuse Block: Service and Repair Instrument Panel Electrical Center or Junction Block Replacement - Left Side Instrument Panel Electrical Center or Junction Block Replacement - Left Side Page 18697 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 21504 Page 9339 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 8142 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 17665 1. Install the lower ball joint in the knuckle. 2. Install upper ball joint in the knuckle. 3. Install the outer tie rod end in the knuckle. 4. Install the wheel bearing and hub assembly. 5. Install the wheel drive shaft, if equipped. 6. Install the tire and wheel. 7. Remove the support and lower the vehicle. 8. Verify the wheel alignment. Refer to Wheel Alignment Specifications. Page 1701 Brake Light Switch: Locations Lighting Systems Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 15302 The list shown is of labor operations for brake service. Disclaimer Page 15029 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten the bolts in the sequence shown to 11 N.m (97 lb in). 15. Ensure that the manual detent spring is aligned properly with the detent lever. Page 14541 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1874 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 11610 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 9709 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 1960 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 19812 Page 243 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 3330 5. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 6. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 7. Remove the TCC solenoid bolts. 8. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 9. Reposition the harness to the side of the transmission case. 10. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 11. Remove the transmission fluid pressure switch. Page 1870 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 1426 Power Seat Motor Position Sensor: Diagrams Power Seat Connector End Views Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) Page 4694 Intake Manifold: Service and Repair Upper Intake Manifold Replacement Upper Intake Manifold Replacement Removal Procedure 1. Remove the fuel pipes/hoses. 2. Disconnect the following electrical connectors: * The A/C pressure switch (1), if equipped * The air conditioning (A/C) compressor clutch (2), if equipped 3. Disconnect the control port injector module (1). Page 24136 Turn Signal Switch: Diagrams Lighting Systems Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Page 12200 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 12396 Transmission Speed Sensor: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 6788 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12647 Page 7949 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 14167 19. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Inspect the rotating torque and adjust if necessary. 20. Install the differential assembly. 21. Fill the axle with lubricant. Use the proper fluid. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 22. Lower the vehicle. Page 21538 Page 7584 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 16494 X502 Left Front Door Harness to Body Harness (ASF+AN3/-YE9) X600 Inline Harness Connector End Views X600 Right Front Door Harness to Body Harness (YE9 -AN3/DL3) Brakes - Aftermarket Trailer Brake Controllers Trailer Brake Control Module: All Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 6216 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 23214 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 22925 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 13259 12. Inspect the transmission fluid pressure manual valve position switch assembly for the following conditions: * Damage * Debris * Damaged or missing O-rings * Cracked connector * Loose electrical terminals * Poor terminal retention 13. Remove the manual detent spring bolt. 14. Remove the manual detent spring. 15. Inspect the manual detent spring for cracks or damage. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 16. Remove the remaining valve body bolts. Page 9425 Installation Procedure Important: The embossed arrow on the MAF/IAT sensor indicates the proper air flow direction. The arrow must point toward the engine. 1. Install the MAF/IAT sensor to the air cleaner assembly. Notice: Refer to Fastener Notice. 2. Tighten the MAF/IAT sensor seal clamp. Tighten the clamp to 4 N.m (35 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 4. Install the air cleaner outlet resonator. Page 5088 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 23893 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 15938 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9147 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 3765 Fluid - A/T: Testing and Inspection 6L50/6L80/6L90 Transmission Fluid Checking Procedure Transmission Fluid Check This procedure checks the transmission fluid level, as well as the condition of the fluid itself. Notice: Always use the proper automatic transmission fluid listed. Using incorrect automatic transmission fluid may damage the vehicle. Before checking the fluid level, perform the following: 1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then, move the shift lever back to PARK (P). 4. Allow the engine to idle 500-800 rpm for at least 1 minute. Slowly release the brake pedal. 5. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center (DIC) or a scan tool. 6. Using the TFT reading, determine and perform the appropriate check procedure. If the TFT reading is not within the required temperature ranges, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. Cold Check Procedure Important: Use this procedure only as a reference to determine if the transmission has enough fluid to be operated safely until a hot check procedure can be made. The hot check procedure is the most accurate method to check the fluid level. Perform the hot check procedure at the first opportunity. Use this cold check procedure to check fluid level when the TFT is between 80°F and 90°F (27°C and 32°C). 1. Locate the transmission dipstick at the rear of the engine compartment, on the passenger's side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe it with a clean rag or paper towel. 3. Install the dipstick by pushing it back in all the way, wait three seconds and then pull it back out again. Important: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection in this procedure. 6. If the fluid level is below the COLD check band, add only enough fluid as necessary to bring the level into the COLD band. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. 7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. 8. Perform a hot check at the first opportunity after the transmission reaches a normal operating temperature between 160°F to 200°F (71°C to 93° C). Hot Check Procedure Important: Us this procedure to check the transmission fluid level when the TFT is between 160°F and 200°F (71°C and 93°C). The hot check procedure is the most accurate method to check the fluid level. The hot check should be performed at the first opportunity in order to verify the cold check. The fluid level rises as fluid temperature increases, so it is important to ensure the transmission temperature is within range. 1. Locate the transmission dipstick at the rear of the engine compartment, on the passenger's side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe it with a clean rag or paper towel. 3. Install the dipstick by pushing it back in all the way, wait three seconds and then pull it back out again. Important: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection. 6. A safe operating fluid level is within the HOT crosshatch band on the dipstick. If the fluid level is not within the HOT band, and the TFT is between 160°F and 200°F (71°C and 93°C), add or drain fluid as necessary to bring the level into the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis. 7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. 8. If applicable and if the vehicle is equipped, reset the transmission oil life monitor only if the fluid was changed. Fluid Condition Inspection Page 7783 Page 3883 Page 7789 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 15916 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 12870 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 14710 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 12133 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 9595 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 4053 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 2996 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 5339 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 1132 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 4030 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 22115 Memory Seat Module X4 (AN3) Page 7593 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 5422 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 12258 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 13798 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 610 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10470 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 217 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Service and Repair Battery Tray: Service and Repair Battery Tray Replacement Removal Procedure 1. Remove the battery. 2. Remove the battery tray front support bolts. 3. Remove the battery tray front support. 4. Remove the nut securing the battery tray to the front fender inner panel. 5. Remove the 3 nuts securing the battery tray to the battery tray bracket. 6. Remove the battery tray from the vehicle. Installation Procedure Page 11890 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 7811 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 21568 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 21876 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Locations Headlamp Dimmer Switch: Locations Lighting Systems Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 1963 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 13571 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 8098 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 15546 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 12132 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 14282 12. Pack the CV joint boot (1) and the CV joint assembly with the grease supplied in the kit. The amount of grease supplied in this kit has been pre-measured for this application. 13. Place the new small boot clamp (2) onto the CV joint seal (1). 14. Slide the CV joint boot (1) onto the halfshaft bar. 15. Position the small end of the CV joint boot (1) into the joint boot groove (3) on the halfshaft bar. Notice: Refer to Fastener Notice. 16. Secure the small boot clamp (1) using J 35910 (or equivalent), a breaker bar, and a torque wrench. Tighten the small clamp (1) to 136 N.m (100 lb ft). 17. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Page 5411 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 4657 15. Install two engine wire harness bracket bolts (1). 16. Install the engine harness and transmission tube bracket bolt (1). Tighten the bolt to 9 N.m (80 lb in). Page 7056 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 4567 Step 8 - Step 16 Page 19819 Electrical - Various Electrical Malfunction/Systems Inop Trailer Warning Indicator: All Technical Service Bulletins Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Page 2401 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 14199 Ring Gear: Service and Repair Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Drive Pinion and Ring Gear Replacement (10.5 Inch Axle) Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the differential assembly. 3. Remove the pinion gear bearing retainer. 4. Remove the pinion and the pinion bearings. 5. Remove the ring gear bolts. Discard the bolts. Notice: Refer to Ring Gear Removal Notice. 6. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary. Installation Procedure 1. If the differential case has become separated, assemble the differential case by aligning the two arrows inside the differential case as shown. Important: The mating surface of the ring gear and the differential case must be clean and free of burrs before installing the ring gear. 2. Install the ring gear to the differential case. 3. Install the new ring gear bolts. Page 2324 Page 16744 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 11457 Page 7486 For vehicles repaired under warranty, use the table. Disclaimer Head Restraint Replacement Head Rest: Service and Repair Head Restraint Replacement Head Restraint Replacement Page 8242 Page 18232 Instrument Panel Outer Air Outlet Replacement - Right Side (with RPO SLT) Instrument Panel Outer Air Outlet Replacement - Right Side (with RPO SLT) Page 21639 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 8097 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 3884 Interior - Power Seat Vertical Motor Inop./Seat Sticks Seat Track: Customer Interest Interior - Power Seat Vertical Motor Inop./Seat Sticks TECHNICAL Bulletin No.: 07-08-50-017A Date: February 22, 2008 Subject: Front Power Seat Vertical Motor Inoperative, Seat Binds or Sticks in Full Up or Down Tilt Position (Install New Stops) Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Impala, Monte Carlo 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL with Adjuster Front Seat Power, Multi-Directional, Driver or Passenger (RPOs AG1, AG2) Supercede: This bulletin is being revised to update the information and the parts quantity. Please discard Corporate Bulletin Number 07-08-50-017 (Section 08 - Body and Accessories). Condition Some customers may comment that the front driver and/or passenger power seat up and down adjustments are inoperative. They may also comment that the seat binds or sticks when in the full up or down tilt position. Cause The cause may be the nylon stop washer (1) being compressed into the lead tilt adjuster screw when in the full up or down tilt position. Correction Install new stops using the procedure below. 1. Verify that the condition is caused by the tilt adjuster screw binding or locked into the full tilt up or down position. 2. Open the hood. 3. Connect a battery charger. Refer to Battery Charging in SI. 4. Toggle the front seat switch down (1) and up (2) with the seat unoccupied. If the seat moves up and down, then proceed to Step 5. Page 6941 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 22704 Tighten the bolts to 22 N.m (16 lb ft). Install the center front seat. Refer to Center Seat Replacement in SI. Install the front seats. Refer to Front Seat Replacement in SI. Install the front seat belts to the seats. Refer to Seat Belt Retractor Pretensioner Replacement in SI. Install the front hinge pillar trim panels. Refer to Body Hinge Pillar Trim Panel Replacement in SI. Install the front door sill plates. Refer to Front Door Sill Plate Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 22337 Rear Seat Cushion Cover and Pad Replacement (Extended Cab with AM7) Rear Seat Cushion Cover and Pad Replacement (Extended Cab with AM7) Page 7408 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 187 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 7932 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 20346 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 3759 Fluid - A/T: Fluid Type Specifications AUTOMATIC TRANSMISSION DEXRON-VI Automatic Transmission Fluid. Page 8554 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 10423 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 3898 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 11398 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Diagrams Combination Switch: Diagrams Lighting Systems Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Page 1337 Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Replacement Rear Object Sensor Replacement Removal Procedure 1. Disconnect electrical from the rear object sensor. 2. Lift the locking tabs on the housing and remove the rear object sensor. Installation Procedure Important: Do not refinish previously painted sensors. Excess paint build up will cause the sensor to be inoperative. 1. Paint the rear object sensor. Refer to Basecoat/Clearcoat Paint Systems. 2. Ensure the paint does not exceed 6 mils. Use a paint thickness gauge suitable for non-ferrous metals. Refer to Paint Gages. Page 6555 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Reposition the knock sensor sleeve (3) down, away from the knock sensor. 4. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. Page 14067 5. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 6. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 7. Remove the TCC solenoid bolts. 8. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 9. Reposition the harness to the side of the transmission case. 10. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 11. Remove the transmission fluid pressure switch. Page 16885 Fuse: Locations I/P Fuse Block Fuse Block - I/P, Label Page 5774 Engine Control Module: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Allison - Automatic Transmission Control Module: Diagrams Allison - Automatic Transmission Automatic Transmission Related Connector End Views Page 16700 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 15914 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 8420 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 13546 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Service and Repair Tail Light Bulb: Service and Repair Tail Lamp Bulb Replacement (Chevrolet) Page 5961 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 3668 12. Remove and discard the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal. 13. Inspect the fluid color. 14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: * Clutch material * Bronze slivers indicating bushing wear * Steel particles 15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material. Installation Procedure 1. Coat the NEW filter seal with automatic transmission fluid. 2. Install the NEW filter seal into the transmission case. Tap the seal into place using a suitable size socket. 3. Install the NEW filter. 4. Install the oil pan and NEW gasket. Page 17433 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 4244 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 18005 Low Tire Pressure Indicator: Description and Operation TIRE PRESSURE MONITOR SYSTEM The Tire Pressure Monitor System (TPMS) uses radio and sensor technology to check tire pressure levels. If your vehicle has this feature, sensors are mounted on each tire and wheel assembly, except the spare tire. The TPMS sensors monitor the air pressure in your vehicle's tires and transmit tire pressure readings to a receiver located in the vehicle. The TPMS is designed to alert the driver, if a low tire pressure condition exists. If your vehicle has the Driver Information Center (DIC), the driver may also check tire pressure levels using the DIC. When a low tire pressure condition is detected, the TPMS will illuminate the low tire pressure warning symbol located on the instrument panel cluster. If your vehicle has the DIC feature, a message to check the pressure in a specific tire will also appear on the DIC display. The low tire pressure warning symbol on the instrument panel cluster and the "CHECK TIRE PRESSURE" warning message on the DIC display will appear at each ignition cycle until the tires are inflated to the correct inflation pressure. You may notice, during cooler weather conditions, that the tire pressure monitor light, located on the instrument panel cluster, and the "CHECK TIRE PRESSURE" message will appear when the vehicle is first started and then turn off as you start to drive the vehicle. This could be an early indicator that the tire pressures are getting low and need to be inflated to the proper pressure. Each tire, including the spare (if provided), should be checked monthly when cold and inflated to the inflation pressure recommended by the vehicle manufacturer on the vehicle placard or tire inflation pressure label. (If your vehicle has tires of a different size than the size indicated on the vehicle placard or tire inflation pressure label, you should determine the proper tire inflation pressure for those tires.) As an added safety feature, your vehicle has been equipped with a tire pressure monitoring system (TPMS) that illuminates a low tire pressure telltale when one or more of your tires is significantly under-inflated. Accordingly, when the low tire pressure telltale illuminates, you should stop and check your tires as soon as possible, and inflate them to the proper pressure. Driving on a significantly under-inflated tire causes the tire to overheat and can lead to tire failure. Under-inflation also reduces fuel efficiency and tire tread life, and may affect the vehicle's handling and stopping ability. Please note that the TPMS is not a substitute for proper tire maintenance, and it is the driver's responsibility to maintain correct tire pressure, even if under-inflation has not reached the level to trigger illumination of the TPMS low tire pressure telltale. Your vehicle has also been equipped with a TPMS malfunction indicator to indicate when the system is not operating properly. The TPMS malfunction indicator is combined with the low tire pressure telltale. When the system detects a malfunction, the telltale will flash for approximately one minute and then remain continuously illuminated. This sequence will continue upon subsequent vehicle start-ups as long as the malfunction exists. When the malfunction indicator is illuminated, the system may not be able to detect or signal low tire pressure as intended. TPMS malfunctions may occur for a variety of reasons, including the installation of replacement or alternate tires or wheels on the vehicle that prevent the TPMS from functioning properly. Always check the TPMS malfunction telltale after replacing one or more tires or wheels on your vehicle to ensure that the replacement or alternate tires and wheels allow the TPMS to continue to function properly. The "CHECK TIRE PRESSURE" warning message and low tire pressure light (telltale) will come on each time the vehicle is started until the tires are inflated to the correct inflation pressure. The Tire and Loading Information label (tire information placard) shows the size of your vehicle's original tires and the correct inflation pressure for your vehicle's tires when they are cold. Your vehicle's TPMS can alert you about a low tire pressure condition but it does not replace normal tire maintenance. NOTICE: Do not use a tire sealant if your vehicle has Tire Pressure Monitors. The liquid sealant can damage the tire pressure monitor sensors. Page 4943 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 8583 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 6125 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 22788 Pull the latch assembly in to gain access to the outer Allen head set screw (1). Loosen the Allen head set screw. Slide the outer set screw and nut assembly (1) out from the rail track. Slide the old latch and spring assembly out of the rail. Slide in the new pull strap latch assembly into the rail track. Install the outer Allen set screw and nut assembly into the rail track. Tighten the set screw. Install the new rail end cover. Roll the tonneau cover up toward the front of the truck bed. Release the right front pull strap latch assembly. Remove the tonneau cover from the side rails. Access the right front pull strap latch assembly. Remove the right front plastic rail end cover from the right front tonneau cover rail. Replace the right front pull strap latch assembly by repeating steps 5-12. Reinstall the tonneau cover. Recall 08V441000: Washer Fluid Heater Overheating Washer Fluid Heater: All Technical Service Bulletins Recall 08V441000: Washer Fluid Heater Overheating MAKE/MODELS: MODEL/BUILD YEARS: Buick/Enclave 2008 Buick/Lucerne 2006-2008 Cadillac/DTS 2006-2008 Cadillac/Escalade 2007-2008 Cadillac/Escalade ESV 2007-2008 Cadillac/Escalade EXT 2007-2008 Chevrolet/Avalanche 2007-2008 Chevrolet/Silverado 2007-2008 Chevrolet/Suburban 2007-2008 Chevrolet/Tahoe 2007-2008 GMC/ Acadia 2007-2008 GMC/Sierra 2007-2008 GMC/Yukon 2007-2008 GMC/Yukon XL 2007-2008 Hummer/H2 2006-2008 Saturn/Outlook 2007-2008 MANUFACTURER: General Motors Corp. MFR'S REPORT DATE: August 27, 2008 NHTSA CAMPAIGN ID NUMBER: 08V441000 NHTSA ACTION NUMBER: EA08010 COMPONENT: Electrical System POTENTIAL NUMBER OF UNITS AFFECTED: 857735 SUMMARY: GM is recalling 857,735 M/Y 2006-2008 Buick Lucerne; Cadillac DTS; Hummer H2; M/Y 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Acadia, Sierra, Yukon, Yukon XL, Saturn Outlook; and M/Y 2008 Buick Enclave vehicles equipped with a heated wiper washer fluid system. A short circuit on the printed circuit board for the washer fluid heater may overheat the control-circuit ground wire. CONSEQUENCE: This may cause other electrical features to malfunction, create an odor, or cause smoke increasing the risk of a fire. REMEDY: Dealers will install a wire harness with an in-line fuse free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact Buick at 1-866-608-8080; Cadillac at 1-800-982-2339 or http://www.cadillac.com; Chevrolet at 1-800-630-2438; Saturn at 1-800-972-8876 or http://www.saturn.com, GMC at 1-866-996-9436; or Hummer at 1-800-732-5493; or mygmlink at http://www.gm.com/recall. NOTES: GM recall No. 08048. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Page 22254 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 5402 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 11362 Page 9702 Vehicle Zoning Strategy Truck Zoning Page 2460 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 7413 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 5448 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 10120 Fuel Pressure: Service Precautions Relieving Fuel Pressure Caution Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 12841 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 971 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 11429 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 23625 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 13230 5. Install the cooler line into the quick connect fitting. 6. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 7. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 8. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 9. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 10. Ensure that the plastic cap is fully seated against the fitting. 11. Ensure that no gap is present between the cap and the fitting. Page 7794 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 620 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 2605 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Specifications Trim Panel: Specifications Fastener Tightening Specifications Page 5475 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 24237 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 7510 Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: * Tearing * Piercing * Arcing * Corroded terminal If corrosion, or arcing are indicated on a spark plug wire boot a terminal, replace the wire and inspect the components connected to the wire. Page 15309 Brake Drum: Removal and Replacement Brake Drum Replacement Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 3501 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Circuit/System Description When the ignition is turned ON, the engine control module (ECM) supplies power to the in-tank fuel pump, by energizing the fuel pump relay. The in-tank fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses. If there are no reference pulses, the ECM turns the in-tank fuel pump OFF, 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running. The electric fuel pump is incorporated into the modular fuel pump and sender assembly and is located inside the fuel tank. The fuel pump supplies fuel through a fuel filter, also located in the modular fuel pump and sender assembly, through the fuel feed pipes, to the fuel rail assembly. The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors. The fuel pressure regulator, located in the modular fuel pump and sender assembly, keeps the fuel available to the fuel injectors at a regulated pressure. When the fuel pressure rises above the pressure regulator calibration, the pressure is relieved, with excess fuel exhausted into the modular fuel pump and sender assembly reservoir. Circuit/System Verification Important: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test review the User Manual CH 48027-5 for Safety Information and Instructions. Ignition ON, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. ‹› If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics 1. Ignition OFF, all accessories OFF, install the CH-48027. Refer to Fuel Pressure Gage Installation and Removal. See: Fuel Pressure Gage Installation and Removal 2. Ignition ON, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and remains steady for 5 minutes. Circuit/System Testing Important: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. Ignition ON, command the fuel pump relay ON with a scan tool and observe the fuel pressure gage while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump. ‹› If the fuel pressure is less than the specified range, remove the fuel tank and test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump. * Restricted fuel feed pipe * Restricted or plugged fuel filter * Restricted or plugged strainer * Stuck or binding fuel level float * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. Important: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel Page 2355 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 1957 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 21498 ` Page 14012 other debris or restrictions are found, then reassemble the valve body and install in the transmission. If the valve body has been contaminated with debris from another transmission component failure, then disassemble all bores for complete cleaning of all valve body components. If possible, keep individual bore parts separated for ease of reassembly. Use the illustrations in this bulletin for a positive identification and location of individual parts: Using GM Brake Clean, or equivalent, in a safe and clean environment (clean aluminum pan), clean the valve body and dry it with compressed air. Use appropriate eye protection. Clean individual valve body components with GM Brake Clean, or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Disclaimer Page 6342 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 17933 Suspension Travel Bumper: Service and Repair Spring Jounce Bumper Replacement (1500) Page 21437 6. Rotate the key until the instrument panel compartment lock cylinder rotates to about the 5 o'clock position. This will line up the notch at the rear of the instrument panel compartment lock cylinder with the tab in the instrument panel compartment latch housing. 7. Remove the instrument panel compartment lock cylinder from the instrument panel compartment latch by pulling on the key. Installation Procedure 1. Position the instrument panel compartment latch fork bolt in the up position. 2. Grasp the instrument panel compartment lock cylinder. Depress the rear-most, light-colored tumbler that is flush with the instrument panel compartment lock cylinder surface. 3. Insert the key. All the tumblers will now stay depressed. 4. Insert the instrument panel compartment lock cylinder, with the key inserted, into the instrument panel compartment latch housing. Ensure that the front projection pin is at the appropriate 8 o'clock position. The instrument panel compartment lock cylinder will drop into place. 5. Rotate the key counterclockwise until the key stops. 6. Remove the key, the tumblers will now release. The instrument panel compartment lock cylinder is now locked into the instrument panel compartment latch housing. 7. Install the instrument panel compartment latch. Refer to Instrument Panel Compartment Door Latch Replacement (without RPO SLT) Instrument Panel Compartment Door Latch Replacement (with RPO SLT) . Instrument Panel Compartment Door Lock Striker Replacement (with RPO SLT) Instrument Panel Compartment Door Lock Striker Replacement (with RPO SLT) Page 15944 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 1559 Wheel Speed Sensor: Diagrams Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Page 236 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 4980 Page 13598 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 20290 3. Insert the sensor into the housing. 4. Connect the electrical connector to the rear object sensor. Page 20747 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 2535 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Locations Accelerator Pedal Position Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 2434 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice Silicon Contamination of Heated Oxygen Sensors Notice Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Page 3824 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (JD9, JF3, JF7) Master Cylinder Replacement (JH6, JH7) * Front Brake Hose Replacement (JD9, JF3, JF7) Front Brake Hose Replacement (JH6, JH7) * Rear Brake Hose Replacement (Caliper - JD9) Rear Brake Hose Replacement (Caliper - JH6, JH7) Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4) Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) Rear Brake Hose Replacement (Frame to Axle JH6, JH7) * Front Brake Caliper Replacement (JD9, JF3, JF7) Front Brake Caliper Replacement (JH6, JH7) * Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JH6, JH7) * Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Brake Pressure Modulator Valve Replacement (JH6, JH7) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (JD9, JF3, JF7) Master Cylinder Replacement (JH6, JH7) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (JD9, JF3, JF7) Master Cylinder Reservoir Replacement (JH6, JH7). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (JD9, JF3, JF7) Front Brake Hose Replacement (JH6, JH7) * Rear Brake Hose Replacement (Caliper - JD9) Rear Brake Hose Replacement (Caliper - JH6, JH7) Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4) Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) Rear Brake Hose Replacement (Frame to Axle JH6, JH7) * Front Brake Caliper Overhaul (JH6, JH7) or Front Brake Caliper Replacement (JD9, JF3, JF7) Front Brake Caliper Replacement (JH6, JH7) * Rear Brake Caliper Overhaul (JH6, JH7) or Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JH6, JH7) * Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Brake Pressure Modulator Valve Replacement (JH6, JH7) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, Page 20069 Vehicle Communication Interface Module (VCIM) X3 (UE1 +U3U/UVB) Page 24205 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Page 17357 X206 Inline Harness Connector End Views X206 Right A-Pillar Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) (U42) OnStar(R) - Language Change Information Navigation System: All Technical Service Bulletins OnStar(R) - Language Change Information Bulletin No.: 05-08-46-009B Date: June 29, 2007 INFORMATION Subject: Language Change for OnStar(R) System (U.S. and Canada Only) Models: 2006-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2008 HUMMER H2, H3 2006-2008 Saab 9-7X with OnStar(R) (RPO UE1) Built After and Including VIN Breakpoints Listed Below (2006 MY Only) Attention: This bulletin only applies to vehicles equipped with OnStar(R) Generation 6.1 or later with a Station Identification (STID) Number in the following range: 16,000,000-17,000,000 or 20,000,000-21,999,999 or 23,500,001-26,000,000 Supercede: This bulletin is being revised to update the service procedure and add a Canadian procedure. Please discard Corporate Bulletin Numbers 05-08-46-009A and 05-08-46-008A (Section 08 - Body and Accessories). Page 10788 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 8525 Page 4831 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure 1. Remove the appropriate spark plug wire boot(s) (2) from the spark plug. (left side shown, right similar). 1. Twist the spark plug boot 1/2 turn. 2. Pull ONLY on the spark plug boot or use a tool designed for this purpose in order to remove the spark plug wire boot from the spark plug. 2. Loosen the spark plug 1 or 2 turns. (left side shown, right similar). 3. Brush or air blast away any dirt from around the spark plug. 4. Remove the spark plug. If removing more than 1 plug, place each plug in a tray marked with the corresponding cylinder number. Installation Procedure Driver Information Display Switch Replacement (without RPO SLT) Driver/Vehicle Information Display: Service and Repair Driver Information Display Switch Replacement (without RPO SLT) Driver Information Display Switch Replacement (without RPO SLT) Instruments - Bulb Outage Detection Restoration Body Control Module: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3211 Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement Inflatable Restraint Vehicle Rollover Sensor Replacement Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Replacement (JD9, JF3, JF7) Front Brake Caliper Replacement (JD9, JF3, JF7) Page 15177 Wheel Speed Sensor: Service and Repair Rear Wheel Speed Sensor Replacement Rear Wheel Speed Sensor Replacement Page 14165 2. Install the inner pinion bearing cup using the J 45870, 8.6 inch axle, or the J 22306, 9.5/9.5LD inch axle, or the J 44417, 11.5 inch axle (2) and the J 8092 (1). 3. Determine the selective shim thickness for the pinion. Refer to Pinion Depth Adjustment (8.6, 9.5/9.5LD, and 11.5 Inch Axles) Pinion Depth Adjustment (10.5 Inch Axle). 4. Install the selective shim between the inner pinion bearing and the shoulder on the gear. 5. Install the inner pinion bearing using the J 24433, 8.6 inch axle, or the J 36614, 9.5/9.5LD inch axle, or the J 44412, 11.5 inch axle. Press the bearing on until the cone seats on the pinion shim. 6. Install a new collapsible spacer. 7. Lubricate the pinion bearings with axle lubricant. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. 8. Install the outer pinion bearing into the axle housing. 9. Install a new pinion oil seal using the J 22388, 8.6 inch, 9.5/9.5LD inch axles, or the J 44414, 11.5 inch axle. 10. Install the pinion into the axle housing. 11. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the splines of the pinion yoke. Page 19716 Page 21503 Trim Panel: Service and Repair Body Lock Pillar Trim Replacement (Extended Cab) Body Lock Pillar Trim Replacement (Extended Cab) Page 8624 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 19109 1 - Door Frame 2 - Window Switch - Driver (A31 -AN3/DL3) 3 - Outside Rearview Mirror - Driver 4 Memory/Heated Seat Switch (AN3) 5 - Outside Rearview Mirror Switch (DL8/DPN) 6 - Driver Door Switch (DDS) (AN3/DL3) 7 - Speaker - Left Front 8 - Window Motor - Driver (A31) 9 - Door Lock Switch - Driver (AU3 -AN3/DL3) 10 - Inflatable Restraint Side Impact Sensor (SIS) - Left Front (ASF) 11 - Door Latch Assembly - Driver Passenger Door Locations Fuel Pressure Sensor/Switch: Locations Engine Controls Component Views Near the Fuel Tank 1 - Fuel Tank Pressure (FTP) Sensor (Gas) 2 - Fuel Tank 3 - Evaporative Emissions (EVAP) Canister 4 - Evaporative Emissions (EVAP) Canister Vent Solenoid Valve (- Diesel) 5 - Electronic Brake Control Module (EBCM) (JL4/JF3/JF7/JH6/JH7) 6 - Fuel Line Pressure Sensor (-LMG/LY6/LC9) 7 - Chassis 8 - Fuel Pump and Sender Assembly - Front (Gas) Page 6541 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Front Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Front Seat Adjuster Switch Knob Replacement Front Seat Adjuster Switch Knob Replacement Page 8191 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Page 18852 11 - Inflatable Restraint Seat Position Sensor (SPS) - Left (10 Series) 12 - Seat Adjuster Assembly - Driver (AG1) 13 - Seat Belt Buckle - Driver Page 22927 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 3553 Ignition Cable: Specifications Spark Plug Wire Resistance................................................................................................................. ...............................................1,200-1,500 ohms per ft Page 16111 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 6951 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 4060 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Locations Auxiliary Battery Relay: Locations Auxiliary Battery Harness (TP2) 1 - Fuse Holder - Underhood 2 - Run Relay 3 - Auxiliary Battery Harness 4 - Auxiliary Battery Relay 5 - X122 Page 15831 7. Install the starter motor bolts. Tighten the bolts to 50 N.m (37 lb ft). 8. Position the starter solenoid cable clip to the frame and install the starter solenoid cable clip bolt (2). Tighten the bolt to 10 N.m (89 lb in). HVAC - Automatic Control Module HVAC: Locations HVAC - Automatic HVAC Component Views HVAC Module 1 - Air Temperature Actuator - Right 2 - Recirculation Actuator 3 - Junction Block - Right I/P C4 4 G200 5 - Blower Motor 6 - Air Temperature Sensor - Lower Right 7 - Air Temperature Actuator Left 8 - Blower Motor Control Module 9 - Air Temperature Sensor - Lower Left 10 - Mode Actuator Page 11884 Page 16453 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) Allison - Automatic Transmission Transmission Mode Switch: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 13106 transmission temperature is below approximately 40°C (104°F). - Harsh or flaring 2-3 shifts that are more likely to occur when the transmission fluid temperature is in the approximately 0°C (32°F) to 40°C (104° F) temperature range, but can be present at any temperature. - Harsh 2-3 shifts that are more likely to occur at less than 50% throttle pressure. Correction Important DO NOT replace the transmission control valve body, transmission control module (TCM) or transmission fluid pump cover assembly. 1. Verify the customer's concern with the described conditions above. Then replace the 1-2-3-4 and 3-5-R clutch fluid seal rings. 2. Remove the transmission assembly from the vehicle. Refer to Transmission Replacement in SI. 3. Remove the transmission oil pan. Refer to Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement in SI. Notice When removing the transmission control valve body, discard the O-ring seals and install new seals, GM P/N 24236927. Failure to install control valve body O-ring seals may cause internal transmission leaks and transmission damage. 4. Remove the transmission control valve body. Refer to Control Valve Body Assembly/Removal in SI. 5. Remove the transmission bell housing / fluid pump. Refer to Torque Converter Housing with Fluid Pump Removal in SI. Notice The three clutch fluid seal rings are required to be installed in a specific way. Failure to install new clutch fluid seal rings may cause internal transmission leaks and transmission damage. 6. Inspect and remove the three clutch fluid seal rings (1). Install new pump rings, GM P/N 24238248. Refer to 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring Installation (6L80/90) in SI for correct installation. 7. After completing the repair procedure, a Service Fast Learn Adapts procedure must be completed. Refer to Service Fast Learn Adapts in SI for procedure details. After completing the Service Fast Learn Adapts procedure, the vehicle may still experience some minor driveability issues but should learn improved shifting performance over the next several key cycles and driving time. Review with the customer the facts about the transmission's ability to self-correct shifting issues or concerns. The transmission adapts are always functional and operate at transmission oil temperatures about 40°C (104°F). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Page 13601 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2162 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 16032 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 13520 Page 21556 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 17135 Fuse Block - I/P X2 Page 17303 X204 Inline Harness Connector End Views X204 Headliner Harness to Instrument Panel Harness (Y91) or I/P Extension Harness (-Y91) (+U42) Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 16054 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 11725 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 15749 15. Ensure that the junction block retainers are in the open position (1). 16. Position and align the junction block to the 4 bracket pivots (2), once the pivots are engaged, push the retainers down into the locked position (3). 17. Install the underhood junction block cover. 18. Connect the auxiliary battery negative cable. Specifications Compression Check: Specifications No cylinder should read less than .............................................................................................................................................................. 690 kpa (100 psi) Page 11060 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 7064 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 18926 Disclaimer Page 13085 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 1900 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Diagram Information and Instructions Fuse: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 11951 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 24277 Sliding Rear Window - Switch (A48) Page 11575 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 7327 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 3636 Disclaimer Page 21698 Passenger Door Switch (PDS) X7 (AN3/DL3) Diagrams Cargo Lamp: Diagrams Lighting Systems Connector End Views Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) X1 Cargo Lamp/Center High Mounted Stop Lamp (CHMSL) X2 Page 16483 X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW/5X7/5Y0) to Right A-Pillar Harness (CF5/TRW/5X7/5Y0) X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness Page 6708 Page 16940 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 10652 17. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 18. Install the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 19. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 20. Install the fuel line clip (1) to the bracket on the automatic transmission. Page 10252 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 2651 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 6758 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 16763 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 11090 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 16174 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 21517 Coat Hook Replacement Coat Hook Replacement Page 3608 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the air conditioning (A/C) system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Page 3115 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 22425 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6744 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 9870 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Interior - Elimination Of Unwanted Odors Seat Cover: All Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Page 5158 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 15935 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 496 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 15100 Transmission Speed Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 7159 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 19792 Disclaimer Page 23597 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 2057 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 21058 8. Remove the pulley (1) from the frame. 1. Lift the end of the tabs (2) out of the window frame (3). 2. Turn upward to release the pulley (1) from the frame (3). 9. Remove the cable ends (1) from the window guide (2) at each end of the window. Page 14336 8. Turn the wheel hub over and install the inner bearing cup. 9. Drive the inner bearing cup into the wheel hub using the J 24427 (2) and the J 8092 (1). 10. Install the inner bearing. Important: The rubber outer sealing rings of the oil seal must be driven into the wheel hub first. 11. Install the new oil seal using the J 44420 (2) and the J 8092 (1). 12. Install the rotor, if necessary. 13. Apply a light coat of high melting point EP bearing lubricant to the axle housing spindle. Page 6650 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 1147 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10772 A/C - Does Not Cool/Can't Change Mode/DTC's Set Control Assembly: Customer Interest A/C - Does Not Cool/Can't Change Mode/DTC's Set Bulletin No.: 07-01-38-009B Date: November 28, 2007 TECHNICAL Subject: EI07264 - Manual HVAC, Temperature or Mode Actuator Performance, A/C Does Not Cool, Unable to Change Mode, DTC B0228, B0413, B0423, B0433, B3779, B3782 (Diagnose for Intermittent Wiring Connection at RH BEC) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra Extended and Crew Cab Models Only with Manual Temperature Control HVAC System (RPO C67) Supercede: This bulletin is being revised to end the need for engineering information and to provide diagnostic procedures to accurately diagnose this condition. Please discard Corporate Bulletin Number 07-01-38-009A (Section 01 - HVAC). Condition This concern only applies to Extended or Crew cab vehicles. If the customer did not bring their vehicle in for this concern, do no proceed with this bulletin. Some customers may comment that the A/C blows hot air or is inoperative. They may also comment that they are unable to change the temperature or HVAC mode of the vehicle. Under these conditions, the actuator has moved to a default position. Refer to the table. Cause Page 9075 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 2436 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Notice Heated Oxygen Sensor Resistance Learn Reset Notice Notice: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required j 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the oil pressure sensor. Do not allow debris to enter the engine. 1. Disconnect the fuel pump/oil pressure sensor electrical connector (3). 2. Using J 41712, remove the fuel pump/oil pressure sensor. Page 2482 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 14704 Page 16935 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 11810 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 16997 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Steering/Suspension - Pitman Arm Shaft Seal Service Kit Pitman Arm: Technical Service Bulletins Steering/Suspension - Pitman Arm Shaft Seal Service Kit INFORMATION Bulletin No.: 10-02-33-001A Date: October 13, 2010 Subject: Information on Pitman Arm Shaft Seal Service Kit Models: 2004-2005 Buick Rainier 2000-2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2000-2005 Chevrolet Blazer, S-10 2000-2011 Chevrolet Avalanche, Express, Silverado, Suburban, Tahoe 2000-2005 GMC Jimmy, Sonoma 2000-2011 GMC Savana, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2000-2004 Oldsmobile Bravada 2003-2009 HUMMER H2 with Recirculating Ball Steering Gears Supercede: This bulletin is being revised to update the model years and models involved. Please discard Corporate Bulletin Number 10-02-33-001 (Section 02 - Steering). Note Do not replace the entire steering gear for a pitman seal leak. Technicians have been replacing entire steering gears due to not being able to service just the leaking pitman shaft seal. The seal is serviced as a kit and is not called out separately in the catalog illustration. The seal package is cataloged in Group 06.855 as Seal Kit - GM Part Number 26002516 - Steering Gear Pitman Shaft, which includes the seal, washer, retaining ring and dust seal or G/M P/N 19256667, which includes the seal and retainer. Refer to Steering Gear Pitman Shaft Seal in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 12261 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 8350 Body Control Module (BCM) X6 Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 23379 Dimmer Switch: Diagrams Lighting Systems Connector End Views Headlamp and Panel Dimmer Switch Page 15955 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Page 20513 15. Clear all codes. Important: Failure to successfully reprogram the BCM may result in the odometer displaying mileage in metric units instead of English units. To reset the odometer to display mileage in English units, remove the 10 amp fuse from the underhood BEC. Do not reinstall the fuse for 5 minutes. Claim Information For vehicles repaired under this service update, use the table. Disclaimer Page 6399 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (1). 4. Gently push in the fuel level sensor retainers (2), disengaging them from the module reservoir. Page 13732 Important: The distance from the torque converter mounting lugs to the transmission mounting face is an important measurement. It is required to check correct reassembly of the torque converter. 6. Measure from the mounting lugs to the transmission mounting face. 7. Install J 46409 180 degrees apart into 2 lugs on the front of the torque converter. Caution: Avoid personal injury or property damage when removing or installing the torque converter by seeking an assistant to help lift the torque converter. 8. Lift the torque converter free of the transmission and place it on the work table. 9. Remove the lifting handles. Installation Procedure 1. Lubricate the converter pump hub OD and the torque converter seal with clean transmission fluid. 2. Install J 46409 180 degrees apart into 2 lugs on the front of the torque converter. Page 11930 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Locations Air Flow Meter/Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 11440 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 5351 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 10219 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 16154 Page 6619 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11993 4. Position the knock sensor heat shield to the engine block and install the bolt. Tighten the bolt to 10 N.m (89 lb in). 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. Interior - Cleaning Interior Surfaces of Vehicle Seat Cover: All Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Diagrams Rain Sensor: Diagrams Wiper/Washer Connector End Views Outside Moisture Sensor (CE1) Locations Steering Mounted Controls Transmitter: Locations Steering Wheel and Column Component Views Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch Assembly - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch Assembly - Left (K34/KA9) Steering Column Harness Page 4592 11. Lower the vehicle. 12. Install the engine mount to engine mount bracket bolts. Tighten the engine mount to engine mount bracket bolts to 65 N.m (48 lb ft). Page 4082 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 16400 X127 Inline Harness Connector End Views X127 Engine Chassis Harness to Generator Jumper Harness (Diesel) Page 14797 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 6195 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 11593 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 7730 During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. BCM Still Fails to Reprogram If the BCM still fails to reprogram perform this procedure: 1. Turn OFF the ignition, and remove the key. 2. Remove the fuses that power up the following modules/components for a minimum of 2 minutes: - BCM - EBCM - ECM - IS LPS (located in the left IP fusebox) - TCM 3. Open and close the driver door. Allow enough time for the retained accessory power (RAP) to turn OFF. 4. Reinstall the fuses. 5. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 6. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8540 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 15330 corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 21045 Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Extended Cab) Rear Side Door Window Regulator Motor Replacement (Extended Cab) A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive Valve Body: Customer Interest A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: This bulletin is being revised to update the models involved and add Condition information. Please discard Corporate Bulletin Number 09-07-30-004B (Section 07 Transmission/Transaxle). Condition Note Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal (1) is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Some customers may comment on any of the following conditions: - Flare or harsh 2-3 shift - Bump/delay in 2-3 shift - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts Cause This condition may be caused by leaking 1-2-3-4 and 3-5-R clutch fluid seal rings. The following conditions are indications that the fluid seal rings may be leaking. - Delayed/extended or delayed with harsh feel initial Park to Drive and/or Reverse to Drive shifts that are more likely to occur when the Page 17169 Fuse Block - Underhood X2 (Pin A1 To M5) Page 24295 Rear Door Window Motor: Service and Repair Rear Sliding Window Module Replacement Rear Sliding Window Module Replacement Removal Procedure Important: The new rear sliding window motor/module is equipped with the bracket and relays. 1. Remove the rear sliding window lower garnish molding. 2. Cycle the rear sliding window to the fully closed position. 3. Remove the screw (1) from the rear sliding window regulator and cables (2). 4. Pull forward on the regulator and cables (2) to release it from the motor/module. 5. Remove the rear sliding window motor/module nuts (2). Page 21890 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 10317 5. Turn the ignition to the OFF position. 6. Relieve fuel pressure and disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287, J 42873 or J 42964 as appropriate for the fuel system. 7. Connect the J 35800-A to the vehicle fuel rail. 8. Pressurize the J 35800-A to 510 kPa (75 psi). 9. Start and idle the engine until it stalls, due to lack of fuel. This should take approximately 15-20 minutes. 10. Turn the ignition to the OFF position. 11. Disconnect the J 35800-A from the fuel rail. 12. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped. 13. Remove the J 37287, J 42873 or J 42964 and reconnect the vehicle fuel feed and return lines. 14. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Pour the entire contents of GM Fuel System Treatment Plus (P/N 88861011 [in Canada, P/N 88861012]) into the tank and advise the customer to fill the tank. 16. Review the benefits of using Top Tier Detergent gasoline with the customer and recommend that they add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure. 17. Road test the vehicle to verify that the customer concern has been corrected. Parts Information * Only 1/8 of the cost may be claimed for 4 and 6 cylinder engines and 1/4 of the cost for 8 cylinder engines. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Warranty Information (Saab U.S. Models) Page 2993 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Page 2652 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 23979 Brake Lamp Relay: Locations TRLR LT STOP/TURN PCB Relay Electrical Center Identification Views Fuse Block - Underhood, Label Page 16256 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 8241 Page 1640 Solar Sensor: Locations HVAC - Manual HVAC Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 10963 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 12980 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Body - Left/Right Power Outside Mirror Inoperative Wiring Harness: Customer Interest Body - Left/Right Power Outside Mirror Inoperative TECHNICAL Bulletin No.: 08-08-45-002A Date: May 13, 2010 Subject: Left Or Right Power Outside Mirror Inoperative (Inspect Wire Harness) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Supercede: This bulletin is being revised to add the 2010 model year and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-45-002 (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside power mirror is inoperative. Cause This condition may be caused by two different concerns. 1. The wiring harness may be damaged from a screw that retains the door trim to the door. 2. The wiring harness connector at the mirror glass actuator may not be locked in place. Correction Inspect the wiring harness and connector. 1. Remove the door trim and inspect the wiring harness. Refer to Front Side Door Trim Panel Replacement in SI if necessary. If the harness is damaged , refer to Repairing Damaged Wire Insulation in SI. After making the repair, reposition the harness. 2. Inspect the connector at the mirror actuator. Refer to Outside Rearview Mirror Motor Replacement in SI if necessary. If the connector is loose, remove and reinstall the connector. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1823 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 9451 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 2256 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 8724 Disclaimer Page 11143 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 13640 Page 18190 Page 20363 - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 7. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 8. Break the tape on the red/black wire and pull it toward the front of vehicle. 9. Remove the lid from the electrical center. Auxiliary Power (Applies to All LD and 2007-2009 HD's Only) Without JL1 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Page 17939 10. Remove the J 36202 from the crossmember. 11. Remove the safety stands and lower the vehicle. 12. Measure the Z height. Page 2670 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Service Precautions Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Notice Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Page 2544 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 19708 Page 15254 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Page 8912 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 10024 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 4000 1 - G111 (XA7) 2 - G108 3 - G110 (XA7) 4 - Brake Booster Assembly 5 - Fuse Block - Underhood 6 - G104 (6A6) Below the I/P Page 3609 Step 1 - Step 7 Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 12553 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 14848 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: Customer Interest Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 3283 11. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 12. Remove the connector from the sensor. 13. Remove the sensor from the adapter and bearing assembly. 14. To install the sensor, proceed to step 9 in the installation procedure. 15. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff (3) for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 16. Remove the connector from the sensor. 17. Remove the sensor clip from the sensor. 18. Remove the sensor from the adapter and bearing assembly. 19. To install the sensor, proceed to step 13 in the installation procedure. 20. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff (3) for installation Page 17147 Junction Block - Left I/P X5 (SPO Alarm) Junction Block - Left I/P X7 (JF4) Page 7099 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 9756 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8001 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 2285 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 16946 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 23631 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 1836 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 17172 Fuse Block - Underhood X4 Suspension - Multiple Noises From Front Of Vehicle Suspension Travel Bumper: Customer Interest Suspension - Multiple Noises From Front Of Vehicle TECHNICAL Bulletin No.: 10-03-08-002A Date: November 03, 2010 Subject: Squeak/Creak/Rumble or Rattle Noise Coming from Front of Vehicle During Low Speed Maneuvers in Cold Ambient Temperatures (Enlarge Upper Inside Diameter (ID) of Strut Jounce Bumper) Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado LD, Suburban LD, Tahoe 2007-2011 GMC Sierra LD, Sierra Denali, Yukon, Yukon XL LD, Yukon XL Denali Supercede: This bulletin is being revised to add the 2011 model year and clarify the text in the Subject, Condition, Cause and Correction. Please discard Corporate Bulletin Number 10-03-08-002 (Section - 03 Suspension). Condition Some customers may comment on a squeak, creak, rumble or rattle noise coming from the front of the vehicle or it may sound like it is coming through the front of the dash, during low speed maneuvers. The noise may be most noticeable in ambient temperatures of 0°C (32°F) or colder. The noise will most likely be heard during small to medium suspension travel such as in parking lot maneuvers, over small bumps, or when stopping. Cause This condition may be caused by the front strut jounce bumper inside diameter to the piston rod of the strut experiencing a slip/stick condition during certain cold ambient temperature conditions. Correction 1. Test drive the vehicle in the same range of ambient temperatures of 0°C (32°F) or colder and the same low speed maneuvers mentioned by the customer in order to verify the concern. 2. Using Chassis Ears, verify that the noise is most noticeable at the upper strut mount area. The concern may be on one or both sides of the vehicle. 3. By jouncing the vehicle, the noise or vibration can be isolated using a stethoscope, and may possibly be felt in the vicinity. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 5. Remove the LH and RH strut assemblies from the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 6. Disassemble the coil spring and top mount assembly from each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. Page 2239 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 6400 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 4951 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Body - Door Latches Freezes in Extreme Cold Front Door Latch: All Technical Service Bulletins Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: The latch and its backing plate have been removed on the above illustration to show the location for the lube. Page 10362 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 7564 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 19921 Page 8980 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 14263 8. Align the hole in the pinion shaft with the bolt hole in the differential case. Notice: Refer to Fastener Notice. 9. Install the new pinion shaft locking bolt. Tighten the bolt to 34 N.m (25 lb ft). 10. Install the rear cover and the gasket. 11. Install the tire and wheel assembly. 12. Fill the rear axle, using the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. 13. Lower the vehicle. Page 13334 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Page 14247 8. Remove the rear axle hub from the axle housing. 9. Remove the rear brake rotor, if necessary. 10. Using a suitable seal removal tool, remove the oil seal from the wheel hub. 11. Remove the inner hub bearing. 12. Using a brass drift and a hammer, remove the inner hub bearing cup. Page 7202 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 21870 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 12625 Shift Solenoid 3 (SS3) Page 17515 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 14800 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 1543 Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution. 1. Disconnect the negative battery cable. 2. Without disconnecting the electrical connectors, remove the left side instrument panel electrical center/junction block and position aside. Refer to Instrument Panel Electrical Center or Junction Block Replacement - Left Side. 3. Disconnect the park brake warning lamp switch electrical connector. 4. Remove the park brake warning lamp switch bolt. 5. Remove the park brake warning lamp switch. Installation Procedure Page 6749 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 10536 Page 6457 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 2456 Page 9609 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 9796 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 4374 Page 1629 Low Pressure Sensor / Switch: Locations HVAC - Manual HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 24207 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 3710 Hose/Line HVAC: Service and Repair Suction Hose Replacement (With RPO Code LY2, LMF, L76 and L92) Suction Hose Replacement (LY2, LMF, L76 and L92) Page 11757 Page 16913 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 11273 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 11613 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 9275 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 7362 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 21523 Page 19803 For vehicles repaired under warranty, use the table above. Disclaimer Page 8429 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 354 Electronic Brake Control Module (JL4) Page 11204 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12824 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 2900 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 11555 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Initial Inspection and Diagnostic Overview Cruise Control: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Cruise Control Begin the system diagnosis with the Diagnostic System Check - Vehicle. The Diagnostic System Check will provide the following information: * The identification of the control modules which command the system * The ability of the control modules to communicate through the serial data circuit * The identification of any stored diagnostic trouble codes (DTCs) and their status See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Page 20655 Owner Letter Owner Letter July 2010 Dear GM Customer: As the owner of a 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, or Yukon XL vehicle, your satisfaction with our product is very important to us. This letter is intended to make you aware that some 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles may have a peeling condition on the top surface of the front or rear chrome interior door handle(s) that could create a rough edge. A chrome plating irregularity combined with direct sunlight exposure may cause the plating to separate from the top surface of the handle. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. What We Have Done: General Motors is providing owners of 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles with additional protection for the front and rear chrome interior door handles. If this condition occurs on your 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, or Yukon XL within 10 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to contact your GM dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference. Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by July 31, 2011. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products. Scott Lawson Director, Customer and Relationship Services Enclosure 09239 Page 17144 Junction Block - Left I/P X2 (Pin A1 To E2) Page 17037 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 2546 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 2745 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 24239 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 14400 5. Remove the bolts (1) and the yoke retainers (2) from the rear axle pinion yoke (4). Notice: When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, the injection joints may fracture and lead to premature failure of the joint. 6. Slide the rear propeller shaft forward in order to remove the propeller shaft from the rear axle pinion yoke. 7. Slide the rear propeller shaft rearward in order to disconnect the rear propeller shaft from the front propeller shaft stub shaft. 8. Remove the rear propeller shaft from the vehicle. 9. Remove the boot from the front propeller shaft stub shaft, if applicable. 10. Remove the center bearing support nuts (1). 11. Remove the center bearing support (2). 12. Remove the front propeller shaft by sliding the front propeller shaft rearward from the transmission or the transfer case, w/o RPO MW7. 13. Remove the bolts and the yoke retainers from the transmission pinion yoke, w/RPO MW7. 14. Remove the front propeller shaft by disconnecting the front propeller shaft from the transmission pinion yoke, w/RPO MW7. Installation Procedure Page 16450 X124 Inline Harness Connector End Views X124 Engine Chassis Harness to PTO Jumper Harness (PTO) Page 21819 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 1817 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 23524 Brake Light Switch: Diagrams Trailer Brake Control Trailer Brake Control Connector End Views Trailer Brake Controller Solid State Relay Trailer Brake Controller Solid State Relay Trailer Brake Control Panel Switch Page 24746 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 6043 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 12149 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 21333 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16703 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6583 Oxygen Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 9524 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 7621 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 11365 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 5286 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 21887 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 7365 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 17843 6. Install the lower ball joint retaining nut. Tighten nuts to 110 N.m (81 lb ft). 7. Install the lower shock absorber module mount bolts. Tighten bolts to 50 N.m (37 lb ft). 8. Remove the support for the steering knuckle and upper control arm. 9. Install the wheel drive shaft, if equipped. 10. Install the stabilizer shaft link to the lower control arm. 11. Install the tire and wheel. 12. Remove the support and lower the vehicle. 13. Align the front end. Refer to Wheel Alignment Measurement. Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 22193 Seat Back: Service and Repair Front Seat Back Frame Replacement Front Seat Back Frame Replacement Page 7996 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 14780 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 2269 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 10458 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 3284 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Page 9866 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 15933 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 17317 X276 Inline Harness Connector End Views X276 Steering Column Harness to Inflatable Restraint Steering Wheel Module Coil (KA9) Page 2848 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Knock Sensor 1 Replacement Knock Sensor: Service and Repair Knock Sensor 1 Replacement Knock Sensor 1 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Remove the knock sensor heat shield bolt and shield. Page 12014 Clutch Control Solenoid Valve: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid, Torque Converter Clutch Solenoid, and Wiring Harness Tools Required J 28458 Seal Protector Retainer Installer Removal Procedure 1. Remove the transmission filter. 2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector. Important: Removal of the valve body is not necessary for the following procedure. 3. Remove the 1-2 accumulator. Do not remove the spacer plate. 4. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) Page 15091 Transmission Position Switch/Sensor: Service and Repair Allison - Automatic Transmission Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Page 10265 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 24736 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 13835 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 14555 Locations Washer Fluid Level Switch: Locations Wiper/Washer Component Views Engine Compartment Components 1 - Battery - Right 2 - Windshield Wiper Motor 3 - Windshield Washer Solvent Heater (XA7) 4 Fuse Block - Underhood 5 - Battery - Left (Diesel/6A6/T92) 6 - Washer Fluid Level Switch 7 Windshield Washer Fluid Pump 8 - Air Cleaner Box Page 18196 Air Door Actuator / Motor: Locations HVAC - Manual HVAC Component Views Interior HVAC Module 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 16079 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 16498 OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 245 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 6978 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 11371 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 9395 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure Page 14278 11. Place a brass drift against the CV joint cage (1). 12. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 13. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 14. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 15. Repeat this process to remove all six of the balls. 16. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (1). At the same time, align the cage windows (3) with the lands of the outer race (2). 17. Lift out the cage (4) and the inner race. Page 20040 Speaker - Left Rear Door (Extended Cab/Crew Cab +UQ3/UQ5) A/T Shift Lock Control Solenoid Speaker - Left Rear Door (Extended Cab/Crew Cab +UQA) Page 7241 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 10988 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 1946 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 22199 Page 21450 Disclaimer Page 22067 For vehicles repaired under warranty, use the table above. Disclaimer Page 8833 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Locations Heated Glass Element Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Page 16150 Fuse Block: Locations HVAC - Manual HVAC Component Views Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 11305 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 24053 7. Align the switch(es) to the front slots as shown. 8. Slide the new switch(es) into the three electrical contact tabs. 9. Align the push button tabs to the lamp switch(es) and install the button(s). 10. Install the dome lamp housing and/or roof console assembly to the headliner panel starting with the right side. Refer to Dome Lamp Replacement and/or Roof Console Replacement in SI. 11. Install the lamp lens. 12. Verify this condition has been corrected by cycling the push button switch(es) four times. Parts Information Warranty Information Important: If the switches were replaced in both locations, the roof console and the center dome lamp, the total time of 0.7 hr should be submitted in regular labor hours. For vehicles repaired under warranty, use the table. Disclaimer Page 20865 Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 8997 3. Position the engine wiring harness lower electrical connector and engage the retainer (3) securing the lower connector (4) to the ECM. 4. Position the engine wiring harness upper electrical connector and engage the retainer (2) securing the upper connector (1) to the ECM. 5. Connect the negative battery cable. 6. If a NEW ECM was installed, program the ECM. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 9402 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 7038 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 10601 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 13582 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 12654 Page 3072 Knock Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 1436 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6417 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 5212 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor from the cylinder head. Installation Procedure Notice: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: Customer Interest A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Page 20112 Disclaimer Page 6671 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 2779 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13621 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 24222 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 11278 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 10999 Locations Timing Component Alignment Marks: Locations * Look to ensure that the crankshaft sprocket is aligned at the 12 o'clock position and camshaft sprocket is aligned at the 6 o'clock position. Page 17949 Page 858 Disclaimer Page 3569 Compression Check: Testing and Inspection Engine Compression Test 1. Ensure that the vehicle batteries are in good condition, and fully charged. 2. Operate the vehicle until the engine is at normal operating temperature. 3. Disconnect the positive ignition coil wire plug from the ignition coil. 4. Disconnect the fuel injector electrical connector. 5. Remove all of the spark plugs. Notice: Do not insert objects into the throttle plate opening. Damage to the throttle body can result, requiring replacement of the throttle body assembly. 6. Block the throttle linkage wide open. 7. Install the engine cylinder compression gage to the cylinder being tested. 8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression strokes, or puffs, for the cylinder being tested. If the engine rotates for more than 4 compression strokes, test the cylinder again. 9. Record the compression reading. 10. Remove the engine cylinder compression gage from the cylinder being tested. 11. Repeat steps 8-11 for each additional cylinder. All cylinders must be tested to obtain valid test results. 12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of engine oil into the cylinder through the spark plug hole. 13. Repeat steps 8-11 for all low compression cylinders. 14. The minimum compression in any one cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kpa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x 70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the lowest allowable pressure in any other cylinder. * Normal The compression builds up quickly and evenly to the specified compression. * Piston rings leaking Compression is low on the first compression stroke. The compression builds up on the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves leaking Compression is low on the first compression stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. * Head gasket leaking Compression is low on the first stroke. The compression does not build up on the following strokes, and does not reach normal. Compression does not improve much, if at all, when you add oil. Adjacent cylinders have the same, or similar, low compression readings. 15. If one or more cylinders fails to meet the minimum specified compression, repair or replace all damaged or worn components and test the engine again. Page 18179 Tip The bad wheel nut cap can be removed by placing a drift or punch inside the center of the nut cap and using a hammer to tap the wheel nut cap out of the hub cap. 4. From inside the hub cap, apply direct pressure to one side of the wheel nut cap rim (1). The wheel nut cap will tip down and pop out of the wheel hub cap hole when enough pressure is applied. Repeat this procedure for any additional wheel nut caps that need to be replaced. 5. Flip the hub cap over on the work bench. The emblem side should be up. Tip A 22 mm (7/8 in) socket placed over the wheel nut cap may be used along with a hammer to tap the new wheel nut cap back into the hub cap hole. 6. Install the new wheel nut cap into the existing hub cap hole by applying direct pressure to the front center of the wheel nut cap. 7. Install the wheel hub cap onto the vehicle and tighten the wheel nut caps. 8. Repeat this entire procedure for each additional hub cap. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6909 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 9751 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 6054 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 16250 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 16028 Locations Auxiliary Power Outlet: Locations Power Outlet Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 13531 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 9150 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 23753 Headlamp Switch: Service and Repair Headlamp Switch Replacement (without RPO SLT) Headlamp Switch Replacement (without RPO SLT) Electrical - Various Electrical System Malfunctions Wiring Harness: All Technical Service Bulletins Electrical - Various Electrical System Malfunctions Bulletin No.: 06-08-45-009 Date: October 31, 2006 TECHNICAL Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on one or all of the following conditions: Rear door locks inoperative Rear windows inoperative Door courtesy lamps inoperative or stay on at times Rear speakers inoperative Any fuse (related to the rear doors) that is blown/shorted SIR codes related to the pretensioner Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction This repair operation is intended to be done on both B-pillars. Remove the lower B-pillar cover. Disconnect the Supplemental Inflatable Restraint (SIR) connector. Inspect the wiring harness in the B-pillar around the seat belt retractor. Make any necessary wiring harness repairs. Wrap the "entire" harness with electrical tape. Install conduit tubing around the harness. O-Ring Replacement A/C Coupler O-ring: Service and Repair O-Ring Replacement O-Ring Replacement Removal Procedure 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure * For compression style fittings use a back up wrench on the fitting (2) and loosen the fitting nut (1). * For banjo style fittings remove the bolt retaining the banjo type fitting. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. Installation Procedure 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. Important: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. 6. The O-ring seal must be fully seated. Page 16018 Page 2345 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 17 Central Control Module: Service and Repair Communication Interface Module Replacement (with RPO SLT) Communication Interface Module Replacement (with RPO SLT) Page 959 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 22177 Power Seat Switch: Diagrams Power Seat Connector End Views Seat Adjuster Switch - Driver (AG1 -AN3) Seat Adjuster Switch - Driver (AN3) Page 12326 Control Module: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Page 21514 Page 9036 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 16178 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 4085 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 17070 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 23560 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 4007 Page 3012 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 443 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 16243 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 3941 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 10535 Page 16788 Auxiliary Power Outlet - Front 1 Auxiliary Power Outlet - Front 2 Page 12731 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 242 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7549 Drivetrain - Updated Transfer Case Speed Sensor Conn. Speed Sensor: Technical Service Bulletins Drivetrain - Updated Transfer Case Speed Sensor Conn. Bulletin No.: 06-04-21-001 Date: May 17, 2006 INFORMATION Subject: Updated Transfer Case Connector Service Kit Now Available For Transfer Case Speed Sensor Wire Harness Connector that Comes Loose Or Connector Retainer Clip Breaks Models: 2007 and Prior GM Light Duty Trucks 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Four-Wheel Drive or All-Wheel Drive Technicians may find that when the transfer case speed sensor wire harness connector is removed, the connector lock flexes/bends and does not return to the original position. The transfer case speed sensor wire harness connector then has no locking device. On older vehicles, the plastic connector retainer becomes brittle and the clip may break as soon as it is flexed. In the past, the only service fix was to install a wire harness connector service pack, P/N 88987183. This repair procedure involved splicing a new service connector with an integral connector lock. This connector service kit is of the same design and was still prone to failure over time. A new connector service repair kit is now available, P/N 15306187, that is an updated design. This new kit should be used whenever the speed sensor wire harness connector requires replacement. Parts Information Disclaimer Page 6466 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7331 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 11561 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 17316 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X275 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness Page 224 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Electrical - Battery Goes Dead Overnight Body Control Module: Customer Interest Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Service and Repair Structural Brace: Service and Repair Front End Sheet Metal Diagonal Brace Replacement Page 22208 Rear Seat Back Cushion Latch Cable Replacement (Extended Cab with AM7) Rear Seat Back Cushion Latch Cable Replacement (Extended Cab with AM7) Page 24203 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15890 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 11083 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 11055 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 16244 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 2666 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Service and Repair Fuel Door: Service and Repair Fuel Tank Filler Door Replacement Page 16726 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 4998 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 8936 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 16008 Page 10935 View of the connector when released from the component. View of another type of Micro 64 connector. Page 16931 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 6793 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 12616 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 18634 and close between 275-317 kPa (40-46 psi). 11. Remove special tool GE-47742 after diagnosis is complete. 12. Install a new O-ring on the A/C low pressure switch port on the accumulator. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. 13. Install the A/C low pressure switch onto the accumulator. Tighten Tighten the A/C low pressure switch to 6 Nm (44 lb in). Important Remember to install the seal back onto the A/C low pressure switch wire harness connector. Failure to replace the seal could result in terminal corrosion. 14. Reconnect the wire harness to the A/C low pressure switch. Disclaimer Page 9219 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 19955 Page 7953 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 2095 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 12205 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 7118 View of the connector when released from the component. View of another type of Micro 64 connector. Page 12844 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 229 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 13809 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 11969 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 14604 Transmission Mode Switch: Service and Repair Transmission Internal Mode Switch Replacement Important: The Internal Mode Switch (IMS) is mounted to the manual shift shaft detent lever as an assembly. The components of the detent lever/IMS assembly cannot be individually serviced. When the IMS needs replacing, the entire assembly must be replaced. Replace the IMS. Refer to Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement. Page 162 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Pressure Regulator Replacement Pressure Regulating Solenoid: Service and Repair Pressure Regulator Replacement Pressure Regulator Replacement Removal Procedure 1. Remove the transmission filter. 2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. 3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). 5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 6. Remove the pressure regulator valve (1). Installation Procedure 1. Install the pressure regulator valve (1). 2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). 3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). 4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. Page 17113 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 7574 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 5076 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 2726 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 13305 6. Remove the wheel chocks before continuing operation of the vehicle. Page 2082 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 3783 5. Remove the rear axle fill plug. 6. Inspect the lubricant level. The lubricant level should be between 0-10 mm (0-0.4 in) below the fill plug opening. 7. If the level is low, add lubricant until the level is even with the bottom edge of the fill plug opening. Use the proper fluid. Refer to Fluid and Lubricant Recommendations. Notice: Refer to Fastener Notice. 8. Install the rear axle fill plug. Tighten the rear axle fill plug to 33 N.m (24 lb ft). 9. Lower the vehicle. Page 8502 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test Circuit/System Verification Important: On the scan tool, the powertrain relay is referred to as the EC ignition relay. 1. Ignition ON, engine OFF, command the powertrain relay ON and OFF several times using the scan tool output control function. You should either hear or feel the relay click with each command. 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate on at least one test point of each fuse. ‹› If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data list. Circuit/System Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit and ground. ‹› If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 3. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 4. Verify that a test lamp illuminates between the relay coil B+ and ground. ‹› If the test lamp does not illuminate, test the relay coil B+ circuit for a short to ground or an open/high resistance. 5. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground or an open/high resistance. If the circuits test normal Service and Repair Horn Switch: Service and Repair Horn Switch Replacement Page 7537 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 8954 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 5332 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 6230 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Interior - Front Door Panel Rattles Loose Front Door Panel: All Technical Service Bulletins Interior - Front Door Panel Rattles Loose TECHNICAL Bulletin No.: 07-08-110-010A Date: April 14, 2008 Subject: EI07321 - Inner Door Panel Rattle Noise/Loose (Inspect/Replace Clips) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Supercede: This bulletin is being revised to end the need for technician feedback and to provide corrective action. Please discard Corporate Bulletin Number 07-08-110-010 (Section 08 - Body and Accessories). Condition Some customers may comment on any of the following conditions: ^ a rattling noise coming from inside the door or the door panel ^ a poor fit of the inner door panel ^ a loose door panel Cause Engineering has determined that some of the door panel clips may have been damaged during assembly. Correction DO NOT REPLACE THE DOOR TRIM PANEL. Remove the interior door panel and inspect the clips for damage. Replace the clips if necessary and reinstall the door panel. If the clips are not missing or damaged, it is possible to correct the customers concern by reinstalling the door panel, ensuring the clips are fully seated. In the event that the customers concern is NOT related to the clips or corrected by reinstalling the door panel submit a Field Product Report (refer to bulletin # 02-00-89-002F). This information will provide engineering with the cause and correction of the customers complaint. Parts Information Important: There are a total of seven (7) white retainers and four (4) black retainers used per door trim panel. The retainers are shipped one per package. The technician will need to determine how many of each retainer is necessary to complete the repair. Warranty Information Page 12600 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 8399 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 10702 Notice: Refer to Fastener Notice. 5. Install the fuel pipe bracket bolt (2). Tighten the bolt to 6 N.m (53 lb in). 6. Install the fuel pipe retainer nuts (1). Tighten the nuts to 3 N.m (27 lb in). 7. Remove the caps from the fuel pipes. 8. Connect the chassis fuel feed pipe (1) to the engine compartment feed pipe. 9. Test the system for leaks using the following procedure: 1. Turn the ignition ON, with the engine OFF for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Page 11537 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 9836 Page 11202 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 2245 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 14929 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 20693 Front Door Latch: By Symptom Technical Service Bulletin # 05-08-64-002B Date: 060403 Body - Door Latches Freezes in Extreme Cold Bulletin No.: 05-08-64-002B Date: April 03, 2006 TECHNICAL Subject: Door Latch Freezing in Cold Temperatures (Apply Super Lube) Models: 2005-2007 GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 05-08-64-002A (Section 08 - Body and Accessories). Condition Some customers may comment on a door latch freezing due to ice accumulation in cold temperatures. Cause Water from a car wash or off the road may have entered the latch and frozen, causing the detent to move slowly. GM Super Lube(R) has been found to be an ideal solution to resolve latch freezing. Correction 1. Verify that the striker properly engages the latch and that no obstructions are preventing the door from closing. Important: Page 4205 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 2336 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 22179 Seat Lumbar Switch - Driver (AN3) Seat Lumbar Switch - Passenger (AN3) Page 1775 Parking Assist System - 'Park Assist Off' Message on DIC Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - 'Park Assist Off' Message on DIC INFORMATION Bulletin No.: 07-08-49-014A Date: July 30, 2008 Subject: Diagnostic Information for Park Assist Off Message on Driver Information Center (DIC) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 07-08-49-014 (Section 08 - Body and Accessories). Some customers may comment that a "Park Assist Off" message is appearing on the Driver Information center (DIC) at times. There are several factors listed above that can cause this message to appear. A Tech 2 can be used to access the latest entry into the Park Assist Module history buffer to help determine a cause. Engineering has received multiple inhibited Rear park Assist Modules through warranty parts return with attached object stored in the latest history buffer. If a vehicle has a trailer hitch installed into the trailer hitch receiver, it is possible for the rear park assist to be disabled. Once the trailer hitch is removed, the message should go away. Other possible causes may be dirty sensors. Keep the rear bumper free of mud, dirt, snow, ice and slush. Important: Please note that any object that is installed in the receiver hitch, extending from the rear of the vehicle, or blocking the sensors can disable the Parking Assist, resulting in the message "Park Assist Off". Please remove the object or obstruction from the vehicle to re-enable the system. This is normal operation of the system. Disclaimer Page 1905 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 17922 7. Remove the jounce bumper (5) from the top mount assembly (3). 8. Secure the jounce bumper upright in a bench vise. Only clamp the lower portion of the bumper to allow the upper portion of the ID to remain at rest. Note A standard drill bit will not cut the ID of the jounce bumper. The jounce bumper will comply and stretch around the bit, then return after the drill is removed. 9. Prepare a single flute countersink bit or a bladed cutting bit, or equivalent, in a die grinder, Dremmel Tool, or equivalent. Page 1605 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Page 3210 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab/Extended Cab/Regular Cab) Page 23933 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 22501 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Locations Battery Current Sensor: Locations Front of Engine Compartment (4.3L) 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor Page 9974 19. Remove the catalytic converter to exhaust manifold nuts (1). 20. Separate the catalytic converter assembly from the exhaust manifolds. 21. Remove the catalytic converter assembly from the exhaust muffler. 22. If replacing the catalytic converter assembly, perform the following steps, otherwise proceed to step 4 in the installation procedure. 23. Remove the exhaust seals (2 and 3). 24. Remove the HO2S (1-4) from the catalytic converter assembly. Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from as exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 17345 X121 Inline Harness Connector End Views X121 Battery Negative Harness to Battery Positive Harness (9L4) X122 Inline Harness Connector End Views X122 Auxiliary Battery Harness to Engine Harness (TP2) OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 11355 Page 10878 Main Relay (Computer/Fuel System): Testing and Inspection Powertrain Relay Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check Vehicle * Review Strategy Based Diagnosis for an overview of the diagnostic approach. * Diagnostic Procedure Instructions provide an overview of each diagnostic category. Typical Scan Tool Data Circuit/System Description The powertrain relay is a normally open relay. The relay armature is held in the open position by spring tension. Battery positive voltage is supplied directly to the relay coil and the armature contact at all times. The engine control module (ECM) supplies the ground path to the relay coil control circuit via an internal integrated circuit called an output driver module (ODM). The ODM output control is configured to operate as a low side driver for the powertrain relay. The ODM for the powertrain relay also incorporates a fault detection circuit, which is continuously monitored by the ECM. When the ECM commands the powertrain relay ON, ignition 1 voltage is supplied to the ECM, and to several additional circuits. Diagnostic Aids This test procedure requires that the vehicle battery has passed a load test and is completely charged. Refer to Battery Inspection/Test. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test Circuit/System Verification Important: On the scan tool, the powertrain relay is referred to as the EC ignition relay. 1. Ignition ON, engine OFF, command the powertrain relay ON and OFF several times using the scan tool output control function. You should either hear or feel the relay click with each command. 2. Ignition ON, engine OFF, with a test lamp, probe both test points of all the fuses that are powered by the powertrain relay. The test lamp should illuminate on at least one test point of each fuse. ‹› If the vehicle passes the Circuit/System Verification test, then operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that are captured in the Freeze Frame/Failure Records Data list. Circuit/System Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Ignition ON, verify that a test lamp does not illuminate between the relay coil control circuit and ground. ‹› If the test lamp illuminates, test the relay coil control circuit for a short to voltage. If the circuit tests normal, replace the ECM. 3. Verify that a test lamp does not illuminate between the relay ignition 1 voltage circuit and ground. ‹› If the test lamp illuminates, test the relay ignition 1 voltage circuit for a short to voltage. If the circuit tests normal, replace the ECM. 4. Verify that a test lamp illuminates between the relay coil B+ and ground. ‹› If the test lamp does not illuminate, test the relay coil B+ circuit for a short to ground or an open/high resistance. 5. Verify that a test lamp illuminates between the relay switch B+ and ground. ‹› If the test lamp does not illuminate, test the relay switch B+ circuit for a short to ground or an open/high resistance. If the circuits test normal Page 10777 Fuel Pump Relay: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 12779 Pressure Regulating Solenoid: Service and Repair Control and Shift Solenoids Replacement Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 9179 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 12801 Page 1886 Battery Current Sensor: Diagrams Battery Current Sensor (10 Series) Battery Current Sensor (10 Series) Page 24690 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 7030 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 12156 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 17153 Junction Block - Left I/P X14 (5Y0/5X7/9L4) Page 2881 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 9691 4. Connect the engine wiring harness electrical connector (2) to the HO2S pigtail electrical connector (1). 5. Install the CPA retainer. 6. Lower the vehicle. Page 17027 Page 8612 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 14939 Torque Converter Clutch Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams 6L50/6L80/6L90 - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Diagrams/Electrical Diagrams Page 1675 Parking Brake Warning Switch: Diagrams Park Brake Switch Park Brake Switch Page 15952 Auxiliary Power Outlet - Front 1 Auxiliary Power Outlet - Front 2 Page 6028 Page 3160 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 12850 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 12977 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 7555 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 12931 Page 5457 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 2415 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 12629 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (367A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Page 8291 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 3702 8. Install the air intake tube. 9. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 6279 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 3152 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 6549 Knock Sensor: Description and Operation Knock Sensor (KS) System Description Purpose The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor (KS) system uses one or 2 flat response 2-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the control module through a low reference circuit. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Page 604 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12519 Page 10111 16. Install the fuel pipe bracket nut to the bellhousing stud. Tighten the nut to 25 N.m (18 lb ft). 17. Position and install the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. 18. Lower the vehicle. 19. Remove the caps from the fuel rail and EVAP line. 20. Connect the EVAP line quick connect fitting (2) to the chassis EVAP line. 21. Connect the fuel feed line (1) quick connect fitting to the fuel rail. 22. Install the fuel fill cap. 23. Connect the negative battery cable. 24. Use the following procedure in order to inspect for leaks: 1. Turn the ignition ON, with the engine OFF, for 2 seconds. 2. Turn the ignition OFF for 10 seconds. 3. Turn the ignition ON, with the engine OFF. Page 485 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Service and Repair Front Steering Knuckle: Service and Repair Steering Knuckle Replacement (1500) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the wheel drive shaft, if equipped. 4. Remove the wheel bearing and hub assembly. 5. Remove the outer tie rod end from the knuckle. 6. Separate the upper control arm from the knuckle. Refer to Upper Control Arm Replacement. 8. Remove the knuckle from the vehicle. Installation Procedure Page 2099 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Discharge Hose Replacement (With RPO Codes LY2, LMF, L76 and L92) Hose/Line HVAC: Service and Repair Discharge Hose Replacement (With RPO Codes LY2, LMF, L76 and L92) Discharge Hose Replacement (LY2, LMF, L76 and L92) Tools Required J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. 3. Remove the discharge hose (1) from the A/C compressor. 4. Remove the upper radiator baffle. 5. Remove the discharge hose nut from the condenser. 6. Remove the discharge hose from the condenser. 7. Disconnect the electrical connector from the A/C recirculation switch. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. Installation Procedure 1. Install the discharge hose (1) to the vehicle. 2. Connect the electrical connector to the A/C recirculation switch. Service and Repair License Plate Bulb: Service and Repair License Lamp Bulb Replacement Page 5539 Tighten the right exhaust manifold pipe bolts in the sequence indicated in illustration "B" above. Tighten: Tighten the bolts to 50 N.m (37 lb ft). Tighten the Y-pipe outlet to the exhaust muffler assembly. Tighten: Tighten to 45 N.m (33 lb ft). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Page 8933 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 5248 For vehicles repaired under warranty, use the table. Disclaimer Page 6986 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 12099 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 10778 Page 21190 Page 9665 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 4505 * The areas surrounding the connections Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap. Page 3122 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 22833 3. Install the weatherstrip to the pinch-weld flange. Ensure that the weatherstrip is fully seated. 4. Install the front door sill plate. Refer to Front Side Door Sill Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Plate Replacement (Extended Cab) . Page 16781 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 6056 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 11038 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 9715 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 13916 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Page 23884 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 9404 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. Page 5406 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 11463 4. Connect the engine wiring harness electrical connector (4) to the CKP sensor. 5. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 6. Lower the vehicle. 7. Perform the crankshaft position system variation learn procedure. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 23890 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR Your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Page 10850 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 7404 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 13840 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 11358 Page 21835 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 15345 Front Brake Caliper Bracket Replacement (JH6, JH7) Front Brake Caliper Bracket Replacement (JH6, JH7) Page 13811 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 550 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 13695 13. Install the cable clips to the floor panel reinforcement. 14. Ensure the transmission manual shaft is positioned in mechanical park. 15. Install the range selector cable to the range selector cable bracket. 16. Install the retainer securing the range selector cable to the bracket. 17. Install the range selector cable end to the transmission range selector lever stud. Locations Steering Mounted Controls Transmitter: Locations Steering Wheel and Column Component Views Steering Wheel Components Steering Wheel Components 1 - Heated Steering Wheel Control Module (KA9) 2 - Horn Switch 3 - Steering Wheel Control Switch Assembly - Right (UK3) 4 - Horn Switch 5 - Steering Wheel Control Switch Assembly - Left (K34/KA9) Steering Column Harness Page 10267 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 11263 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 15314 Brake Shoe: Service and Repair Brake Shoe Replacement Page 4013 Vehicle Zoning Strategy Truck Zoning Page 15348 Page 23628 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 22529 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 7052 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 574 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 209 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 5338 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 6202 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 21894 Page 9202 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 6999 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 11953 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 10854 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 23126 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 1567 Page 11137 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 18648 Solar Sensor: Locations HVAC - Manual HVAC Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 14395 2. Install the propeller shaft boot (2). 3. Install the propeller shaft boot clamp (1). 4. Install the propeller shaft splines into the transfer case output shaft. Page 8356 Low Speed Bus - 2 of 3 Page 24194 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 24294 Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement (Extended Cab) Rear Side Door Window Regulator Motor Replacement (Extended Cab) 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission: * The torque converter clutch solenoid (1) * The pressure control solenoid (2) * The internal wiring harness (3) * The 2-3 shift solenoid (4) * The 1-2 shift solenoid (5) * The transmission fluid pressure manual valve position switch (6) * The 3-2 shift solenoid (7) * The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wiring harness electrical connectors from the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) Page 17909 Shock, Shock Component, and/or Spring Replacement Shock, Shock Component, and/or Spring Replacement Page 8394 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 16452 X126 Inline Harness Connector End Views X126 Instrument Panel Harness to Chassis Harness (-JL4) Page 10255 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 21775 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Page 16194 View of the connector when released from the component. View of another type of Micro 64 connector. Page 8889 Vehicle Zoning Strategy Truck Zoning Page 15866 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 6777 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 16573 Inspect how the IP branch to C202 is routed. Reroute the wiring as necessary to match the correct routing in the photo above. In order to route the IP harness branch correctly (behind the junction block-left I/P): Remove the cover from the junction block-left I/P, unseat the junction block from the bracket. Disconnect C202. Route the harness such that it lays between the goalposts of the junction block bracket. Seat the junction block to the bracket (harness will now be under the junction block). Secure the harness by seating the grey offset retaining clip to the dashmat (or brown "buddy clip" if present - usually on SUV's only). Reconnect C202. Make sure that the grey offset retaining clip (off of the IP branch going to C202) is seated into the hole in the dashmat or into the brown buddy clip (if present), securing the IP branch to the vehicle. If the harness is still in contact with a sharp edge or point of the park brake assembly, protect the harness by routing it away from the contact point and holding it there with tie straps, and/or covering the sharp edge with butyl tape. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13926 Transmission Pressure Test Port: Service and Repair Allison - Automatic Transmission Automatic Transmission Fluid Pressure Test Hole Plug Replacement Removal Procedure 1. Remove the pressure tap plug (2) and O-ring (1) on the bottom of the converter housing near the transmission external oil filter. 2. Remove the O-ring from the plug and discard it. Installation Procedure 1. Install a new O-ring (1) on the pressure tap plug (2). Notice: Refer to Fastener Notice. Page 22996 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 14402 7. Install the boot (3) and 2 new clamps (2) onto the front propeller shaft stub shaft (4), if applicable. 8. Install the rear propeller shaft slip yoke onto the front propeller shaft stub shaft. Mate the missing tooth in the yoke with the bridged tooth on the splined shaft. 9. Install the rear propeller shaft onto the rear axle pinion yoke. Align the reference marks made during removal. 10. Install the yoke retainers (2) and the bolts (1). Tighten the yoke retainer bolts to 25 N.m (18 lb ft). 11. Using the J 43218, crimp the boot clamps until the dimensions shown are obtained. 12. Lower the vehicle. Page 24519 Page 895 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Page 18659 Solar Sensor: Locations HVAC - Manual HVAC Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 15368 Brake Fluid Level Sensor/Switch: Diagrams Brake Fluid Level Switch Brake Fluid Level Switch Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Module Replacement Page 433 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 16491 X416 Inline Harness Connector End Views X416 Rear Bumper Harness to Right Hip Lamp Harness (RO5) Page 12130 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 7986 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 9077 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Page 23551 Page 12728 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Rear Object Sensor Housing Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement Rear Object Sensor Housing Replacement 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Page 23102 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 6655 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Page 8599 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 15769 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.3L) Removal Procedure 1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Page 19493 Method 1 Method 2 Page 16607 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 9409 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 24610 12. Fill the washer solvent container with windshield solvent. Refer to Fluid and Lubricant Recommendations. Page 9638 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 18400 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 191 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 9789 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 20512 position of the ignition switch during the programming procedure, unless instructed to do so. Make certain all tools connections are secure, including the following components and circuits: ^ The RS-232 communication cable port ^ The connection at the data link connector (DLC) ^ The voltage supply circuits DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur. DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Tech 2 Pass-Thru Method for the Body Control Module (BCM) 1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Use an additional jump battery if necessary. ^ If the vehicle will not start, test and charge the battery. Refer to SI for battery testing and charging information, if required. ^ If the battery will not hold a charge, replace the battery/Do NOT replace the battery unless it can't be charged or a leak and/or physical damage is present. 2. Connect the Tech 2 to the vehicle and the TIS terminal. 3. Turn the ignition to the ON position with the engine OFF. 4. After all warning chimes inside the vehicle have stopped, turn on the Tech 2. 5. On the TIS terminal go into SPS Programming. 6. Select Pass Thru programming. 7. Follow instruction on the TIS terminal. When you get to the Supported Controllers screen. 7.1. Scroll down in the top box and select BCM (Body Control Module). 7.2. In the lower box select Normal. 7.3. Select Next. Important: Vehicles without the Driver Information Center (DIC) and power door locks/windows will have two calibrations from which to choose. A selection is required before you can select NEXT. Select calibration 25814828. Do not select calibration 25788372. 8. Select NEXT when the calibrations screen displays. 9. Follow on-screen prompts until programming is completed. 10. When programming is complete. 10.1. Turn off Tech 2. 10.2. Turn the ignition switch to the OFF position. 11. Wait 30 seconds. 12. Turn the ignition switch to the ON position with engine OFF. 13. Turn on the Tech2. 14. Go into diagnostics and check for DTC codes. Page 11571 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2476 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Electrical - Various Electrical System Malfunctions Wiring Harness: All Technical Service Bulletins Electrical - Various Electrical System Malfunctions Bulletin No.: 06-08-45-009 Date: October 31, 2006 TECHNICAL Subject: Rear Door Locks/Rear Windows/Courtesy Lamps/Rear Speakers Inoperative, Blown Fuse, SIR DTC Codes (Inspect/Repair, Wrap Wire Harness) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado (Crew Cab Only), Suburban, Tahoe 2007 GMC Sierra (Crew Cab Only), Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment on one or all of the following conditions: Rear door locks inoperative Rear windows inoperative Door courtesy lamps inoperative or stay on at times Rear speakers inoperative Any fuse (related to the rear doors) that is blown/shorted SIR codes related to the pretensioner Interior dimming inoperative Cause The B-pillar wiring harness around the seat belt retractor may be or become chaffed/damaged. The correction listed below is intended to repair any damage and prevent future concerns. Correction This repair operation is intended to be done on both B-pillars. Remove the lower B-pillar cover. Disconnect the Supplemental Inflatable Restraint (SIR) connector. Inspect the wiring harness in the B-pillar around the seat belt retractor. Make any necessary wiring harness repairs. Wrap the "entire" harness with electrical tape. Install conduit tubing around the harness. Page 5978 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 23396 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 2972 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 12697 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 23943 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 22600 Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Passenger Side Door Lock and Side Window Switch Replacement - Passenger Side Page 8162 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Diagrams Outside Temperature Display Sensor: Diagrams Mirror Connector End Views Ambient Air Temperature Sensor (DF5) Page 19820 Diagnostic Tips Review # 3 - Denso Navigation Radios Page 16198 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 10102 1. Position and install the fuel/EVAP line assembly to the vehicle. 2. Install the fuel/EVAP line bracket locator tab to the frame. 3. Install the fuel/EVAP line clips to the frame and crossmember. Notice: Refer to Fastener Notice. 4. Install the fuel/EVAP line bracket bolt (1). Tighten the bolt to 9 N.m (80 lb in). 5. Install the fuel/EVAP line clip nut (2). Tighten the nut to 20 N.m (15 lb ft). 6. Remove the caps from the fuel and EVAP lines. 7. Connect the chassis EVAP line quick connect fitting to the EVAP canister. 8. Connect the fuel tank fuel feed line quick connect fitting to the chassis line. Page 24743 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 5161 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 12312 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 8079 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 4928 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Specifications Water Pump: Specifications Water Pump Bolt ................................................................................................................................. .......................................................... 45 N.m 33 lb ft Page 8606 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 17084 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 4436 Important: Whenever a new camshaft is installed, perform the following: * Change the engine oil and filter. * Add engine oil supplement to the engine oil. Refer to Sealers, Adhesives, and Lubricants for the correct part number. Apply lubricant or engine oil supplement to the following components: * The engine camshaft lobes * The camshaft bearing journals * The camshaft bearings Refer to Sealers, Adhesives, and Lubricants for the correct part number. 2. Install three 5/16-18 x 4.0 inch bolts into the engine camshaft front bolt holes. Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the camshaft bearings. 3. Using the bolts as a handle, install the engine camshaft. 4. Remove the 3 bolts from the front of the engine camshaft. 5. If reusing the fasteners, apply threadlocker to the threads of the camshaft retainer bolts. Refer to Sealers, Adhesives, and Lubricants for the correct part number. Notice: Refer to Fastener Notice. 6. Install the camshaft retainer and bolts. Tighten the bolts to 12 N.m (106 lb in). 7. Install the balance shaft drive gear. 8. Install the timing chain and camshaft sprocket. 9. Install the lifters. 10. Install the A/C condenser. 11. Install the radiator. Page 17983 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Page 10793 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 11837 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 8281 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 3089 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6997 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 478 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 4138 Junction Block - Right I/P (Wire Entry) (Pin 4B7 To 6B) Junction Block - Right I/P X2 Emissions - MIL ON/DTC P0446 Stored In ECM Evaporative Canister Filter: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 2489 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 13400 Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 09-07-30-004C Date: 110113 A/T - Shift Flare/Harsh 2-3 Shifts/Harsh Park To Drive TECHNICAL Bulletin No.: 09-07-30-004C Date: January 13, 2011 Subject: Flare and/or Harsh 2-3 Shifts, Delayed/Extended or Delayed with Harsh Feel Initial Park to Drive and/or Reverse to Drive Shifts (Install Three Fluid Seal Rings) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Suburban 2009 Chevrolet Avalanche, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon Denali, Yukon XL Denali 2008-2009 GMC Yukon XL 2009 GMC Yukon Equipped with 6L80 (RPO MYC) or 6L90 (RPO MYD) Automatic Transmission Vehicles Built Prior to December 2008 Attention: Vehicles built prior to December 2008 are more likely to have leaking fluid seal rings. Starting in November 2008, a new 2-piece seal was implemented. When the transmission pump is removed and a 2-piece seal is found, do not continue on with this bulletin. The guidelines of this bulletin will not apply to a 2-piece seal. Supercede: Page 9158 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 3480 Alignment: Description and Operation Caster Description Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Page 22129 Memory Seat Module X4 (AN3) Page 3700 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Remove the air intake tube. 3. Remove the heater and surge tank hoses from the mounting clip. 4. Squeeze the plastic retainer release tabs. 5. Pull the connection apart. 6. Remove the outlet heater hose from the water pump. 7. Reposition the outlet heater hose clamp at the surge tank. 8. Remove the outlet heater hose from the surge tank. Page 1950 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8123 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14117 5. Repair or replace the terminal(s) as needed. Refer to the instructions in the J-38125 manual. 10. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 11. Slide the new terminal(s) into the correct cavity at the back of the connector until it locks in place. The new terminal(s) should be even with the other terminal(s). 12. Ensure that each terminal is locked in place by gently pulling on the wire. Note The male terminal(s) cannot be repaired as they are an integral part of the transmission control module (TCM). 13. Inspect for bent or misaligned terminal(s) in the transmission half of the electrical connector. ‹› If they are bent, use a suitable tool and apply gentle pressure to straighten them. Indicate on the repair order the terminal number of the male terminal that was bent. ‹› If they are damaged, refer to Control Solenoid Valve and Transmission Control Module Assembly Replacement in SI. 14. Prior to installing the transmission connector, perform the following steps to ensure that the TPA lock is fully seated. Locate the TPA lock in the reassembled transmission connector. Refer to the arrow in the illustration above, which points to a TPA lock. This one is in an unseated position. Using a small flat blade tool, push to seat the TPA until it bottoms out. Verify the TPA is fully seated. - If the TPA is off-center in the check window as shown, then it is only partially seated. Note the large gap at the arrow. Reseat the TPA lock and ensure that it is fully seated. - If the TPA lock is centered in the window as shown, then it is fully seated. The gaps shown by the arrows should be even on both sides. 15. Install the transmission 16-way electrical connector. Page 12804 Vehicle Zoning Strategy Truck Zoning Page 16631 7. Install the lower B-pillar cover. Parts Information Warranty Information Important: The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. For vehicles repaired under warranty, use the table above. Disclaimer Page 12241 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23080 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 17717 Removal Procedure 1. Place drain pans under the vehicle as needed. 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. Notice: Refer to Power Steering Hose Disconnected Notice. 3. Disconnect the power brake booster outlet hose (1) from the power brake booster (2). 4. Disconnect the power brake booster outlet hose (1) from the power steering fluid reservoir (3). 5. Remove the power brake booster outlet hose (1) from the vehicle. Installation Procedure Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 1. Install the power brake booster outlet hose (1) to the vehicle. 2. Connect the power brake booster outlet hose (1) to the power steering fluid reservoir (3). 3. Connect the power brake booster outlet hose (1) to the power brake booster (2). 4. Clean any excess fluid from the vehicle and remove the drain pans. 5. Fill and bleed the power steering system. Page 1015 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 22404 Page 9459 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 14685 2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395). 3. Install the 1-2 shift solenoid (367A) and the 1-2 shift solenoid retainer (395). Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body; otherwise, the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Important: When installing the pressure control solenoid, the electrical connector must be in the position 1 shown. Do not use position 2. 4. Install the pressure control solenoid (377). Notice: Refer to Fastener Notice. 5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Page 8956 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 23115 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 4137 Junction Block - Right I/P (Wire Entry) (Pin 2A1 To 4B6) Page 440 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 12335 Fluid Pressure Sensor/Switch: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 11153 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 11340 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 24538 Disclaimer Service Procedure Service Procedure Technicians are to confirm that the customer is aware that this safety recall is being performed on their vehicle prior to performing the repair. If a customer refuses to have this safety recall performed on their vehicle, dealers are to provide the customer with a copy of the "Notice to Customer" document provided in this bulletin, record on the repair order "customer declined recall repair" and, if possible, have the customer sign the repair order. A labor code is provided for customers who refuse the repair. This labor code will not close the recall. If the customer, or a new owner, decides at a later date to have the recall performed, perform the repair and submit the claim using the appropriate V labor code. This service procedure will permanently disable and remove the heated windshield washer fluid system. After performing the procedure, dealers are to issue a $100 USD/$105 CDN check to the customer of record as compensation for the loss of this feature (see Q&A; section of this bulletin for additional details). Involved vehicles currently in dealer/retailer new or used car inventory are not eligible for a check. However, all new vehicles currently in dealer/retailer inventory will be re-invoiced with appropriate dealer credit for the elimination of this feature. Fuse Removal FUSE REMOVAL 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT, 2007-2009 Chevrolet Avalanche, Silverado (GMT900), Suburban, Tahoe, 2007-2009 GMC Sierra (GMT900), Yukon and Yukon XL 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. Note The underhood fuse block is located in the engine compartment on the driver side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 2. Locate the underhood bussed electrical center (UBEC). 3. Remove the UBEC cover and locate the 60 amp heated windshield washer fuse. Service and Repair Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Page 10693 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip (1) from the bracket on the automatic transmission. 9. Unclip the oxygen sensor harness connector from the bracket. 10. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 20382 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 10288 Disclaimer Page 279 Outside Rearview Mirror References Page 14070 21. Remove the spacer plate support bolts (77). 22. Remove the spacer plate support (53). 23. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse. Installation Procedure 1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47). Notice: Refer to Fastener Notice. 2. Install the spacer plate support (53) and bolts (77). Tighten the bolts to 10 N.m (89 lb in). Page 7414 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 15481 Notice: Refer to Fastener Notice. 3. Install the park brake cable clip bolt (2). Tighten the bolt to 22 N.m (16 lb ft). 4. Connect the park brake cable (1) to the rear axle housing cover clip. 5. Insert the park brake cable conduit (2) into the frame bracket. Ensure the locking tabs on the cable conduit are fully engaged into the frame bracket. 6. Connect the right rear park brake cable to the equalizer (1). 7. Enable the park brake cable automatic adjuster. Refer to Parking Brake Cable Adjuster Enabling. 8. Adjust the park brake. Refer to Park Brake Adjustment (Disc Brake) Park Brake Adjustment (Drum Brake). Park Brake Cable Guide Replacement Page 2453 Page 6615 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 1106 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 10974 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 11748 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Caution Caution: Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 14213 1. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. 3. Install the axle shaft seal using the J 21128. 4. Drive the tool into the bore until the axle shaft seal bottoms flush with the tube. 5. Install the axle shaft. Rear Axle Shaft and/or Gasket Replacement Rear Axle Shaft and/or Gasket Replacement Removal Procedure 1. Remove the flange bolts. 2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft. Locations Ignition Control Module: Locations Engine Controls Component Views Rear of the Engine 1 - Central Sequential Fuel Injection (SFI) Module 2 - Manifold Absolute Pressure (MAP) Sensor 3 G106 4 - Engine Oil Pressure (EOP) Sensor 5 - Ignition Control Module (ICM) 6 - G107 Page 8116 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Page 10259 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 16776 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 5852 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 12119 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 22962 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 12145 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 15884 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Diagrams Shock Sensor: Diagrams Theft Deterrent System Connector End Views Shock Sensor (SPO Alarm) Page 3019 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 8879 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Page 3992 Page 13637 4. Remove the solenoid retainer (6) for shift solenoid 2 (SS2) (1) or shift solenoid 3 (SS3) (4), whichever is being replaced. 5. Note the position of the solenoid connector and pull the solenoid out of the bore in the control valve assembly. The O-rings (2 and 3) provide the resistance felt during removal. Important: The TCC pressure control solenoid (PCS) retaining bracket must not be modified. Note that the angle between the 2 bracket surfaces is less than 90 degrees. Replace the bracket if the angle is 90 degrees or greater. 6. Remove the TCC PCS retaining bolt and retaining bracket. 7. Remove the TCC PCS (7). Installation Procedure 1. Obtain a new SS 2 (1), SS 3 (4), TCC PCS (7), or modulated main pressure solenoid. Install O-rings (2 and 3) and lubricate with clean transmission fluid. Push the new solenoid into the control valve assembly (5) with the wiring harness connector in the correct position. 2. Install the solenoid retainer (6). Connect the internal wiring harness to the solenoids replaced. Page 449 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 9233 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 5417 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 5276 Page 6552 4. Reposition the knock sensor sleeve (2) down, away from the knock sensor. 5. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. 6. Remove the knock sensor bolt and sensor. Installation Procedure Page 21909 Memory Positioning Module: Service and Repair Memory Seat Control Module Replacement Page 4875 Page 9656 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Resonator Replacement Removal Procedure 1. Disconnect the positive crankcase ventilation (PCV) hose (1) from the air cleaner outlet resonator. 2. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 3. Loosen the air cleaner outlet resonator clamp (2) at the throttle body. 4. Remove the air cleaner outlet resonator from the throttle body and the MAF/IAT sensor. Installation Procedure Page 6292 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 24251 Endgate Cable Replacement Tailgate Shock / Support: Service and Repair Endgate Cable Replacement Endgate Cable Replacement Page 4091 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 12589 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 13925 1. Install the oil pressure test plug. Tighten the oil pressure test plug to 11 N.m (97 lb in). 2. Check the transmission fluid level (fill if necessary). 3. Lower the vehicle. Page 7358 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 3203 Page 5150 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 6652 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 5817 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 9237 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 16240 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Service and Repair Keyless Entry Transmitter Battery: Service and Repair Transmitter Battery Replacement Removal Procedure 1. Insert a small bladed tool, at the slot provided near the key ring hole (5), between the two halves (6, 4) of the transmitter case. 2. Twist the small bladed tool, between the two halves in order to separate the case. 3. Remove the battery (2) from the transmitter. Installation Procedure 1. Install the battery (2) with the positive side down into the transmitter. 2. Ensure the seal (7) is in position. Align the two halves of the case (6, 4), and snap the two halves together. 3. Verify the operation of the transmitter. Page 18746 Air Bag Control Module: Diagrams SIR Connector End Views Inflatable Restraint Sensing and Diagnostic Module (SDM) (Extended/Crew Cab +10 Series +ASF) Page 16200 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 10578 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 23612 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 4319 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 3083 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 6215 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 3485 D Height Measurement Important: The left and right D height difference should be no more than 14 mm (0.55 in). Use the following procedure to measure the D height. 1. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. Measure between the axle bracket and jounce bumper mount bracket as shown in graphic. 5. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 6. Gently remove your hands and let the vehicle settle. 7. Repeat this operation 2 more times for a total of 3 times. 8. Re-measure the D height as in step 4. 9. The true D height is the average of the measurement from step 4 and step 8. The side to side difference in D height must not exceed 14 mm (0.55 in). 10. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Page 21830 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Service and Repair Steering Wheel Heater Control Module: Service and Repair Steering Wheel Heat Module Replacement Page 17301 Page 6066 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: Customer Interest Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 23315 Customer TPMS Information Page 6119 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 23118 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Locations Power Seat Motor Position Sensor: Locations Power Seat Component Views Driver Seat 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (AN3) Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 21968 6. Lift upward on the sunshade (1) removing it from the bracket (2). Important: The sunshade must be removed from the top of the vehicle. 7. Push the sunshade (1) inward to the driver side releasing it from the bracket (2) notch. 8. Remove the sunshade from outside of the vehicle. Installation Procedure 1. Install the sunshade to the vehicle from the passengers side. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 18705 If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Scott Lawson Director, Customer and Relationship Services Page 3000 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3771 Fluid - A/T: Service and Repair Allison - Automatic Transmission Automatic Transmission Fluid and Filter Replacement Removal Procedure Important: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. Important: Use a standard strap-type filter wrench to remove the transmission external oil filter. 3. Remove the filter (4) by rotating in the counterclockwise direction. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Notice: Refer to Fastener Notice. 5. Install the drain plug (6) and drain plug seal (5). Tighten the drain plug to 35 N.m (26 lb ft). 6. Refill Transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. Important: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. Page 551 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 2795 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 24440 5. Install the rear sliding window pulley (1). 1. Align the tabs (2) on the pulley (1) with the notch in the frame (3). 2. Turn the pulley downward, locking the pulley into the frame (3). 6. Install the regulator cables (2) to the retainers (1) across the bottom edge of the window frame. Page 11954 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 23819 1. Remove the instrument panel (I/P) knee bolster. Refer to Knee Bolster Replacement in SI. 2. Remove the park brake release handle. Refer to Park Brake Release Handle Assembly Replacement SI. 3. Locate the left bussed electrical center (LBEC), which is located on the left end of the instrument panel IP. 4. Locate the 40-way connector X1 that is attached to the back of the LBEC. 5. Disconnect the 40-way connector X1 from the LBEC. Body - Side Door Body Mounted Weatherstrip Replacement Front Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 15255 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Page 15004 Control Module: Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Related Connector End Views Transmission Control Module (TCM), Engine Side Page 18786 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Inflatable Restraint Side Impact Sensor Replacement (Crew Cab) Page 11696 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 14805 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Allison - Automatic Transmission Transmission Mode Switch: Locations Allison - Automatic Transmission Automatic Transmission Electronic Component Views Engine Harness to Transmission Engine Harness to Transmission 1 - Turbine Sensor Harness Connector 2 - Power Take-Off (PTO) Connector 3 - Output Speed Sensor Harness Connector 4 - Transfer Case Selector Shift Control Switch 5 - Transmission Connector Harness 6 - Allison Transmission 7 - Engine Harness 8 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 13749 Page 17306 X207 Inline Harness Connector End Views X207 I/P Harness to I/P Harness (6J4) Page 14725 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 4885 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 23074 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 23735 Headlamp Bulb: Service and Repair Headlamp Bulb Replacement (Chevrolet) Page 510 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 2233 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 4803 * The areas surrounding the connections Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap. Page 11769 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 6472 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 21920 Memory Seat Module X3 (AN3) 07-08-44-013A - END OF NEED FOR INFORMATION Speaker: All Technical Service Bulletins 07-08-44-013A - END OF NEED FOR INFORMATION ENGINEERING INFORMATION Bulletin No.: 07-08-44-013A Date: July 16, 2009 Subject: EI07199 - Radio Speaker Buzz Noise (Engineering Information Closed) Models: 2007 Chevrolet Silverado 2007 GMC Sierra Supercede: This bulletin is being revised to end the need for information from the field. Please discard Corporate Bulletin Number 07-08-44-013 (Section 08 - Body and Accessories). GM Engineering investigated vehicles with your assistance in the field, but did not identify a single point issue (root cause) for this condition. Due to this cooperation, engineering is satisfied with the data collected and requires no further response. Please refer to SI and use the established diagnostic information to correct the customer concern. Disclaimer Locations Sunroof / Moonroof Module: Locations Sunroof Component Views Sunroof Module 1 - Sunroof Module 2 - Left Outer Frame Panel Page 2568 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Page 23011 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 8457 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 13829 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 15694 Specifications Transmission Temperature Sensor/Switch: Specifications Transmission Fluid Temperature Sensor Specifications Transmission Fluid Temperature Sensor Specifications Page 4026 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 15913 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 1861 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 2703 Technician Safety Information Information Bus: Technician Safety Information Data Communication Schematic Icons 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 7054 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 21338 If the customer still expresses a concern about the slit show the customer another comparable vehicle. The new body style pickup and utility will have the same floor trim line with the access cover (1) under the left front seat. The access cover should be pulled back and pressed down for the best appearance. Disclaimer Page 18640 Low Pressure Sensor / Switch: Diagrams HVAC - Manual HVAC Connector End Views A/C Low Pressure Switch (C67) Reverse Lockout Solenoid Page 10374 Page 15576 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement Page 9136 Locations Torque Converter Clutch Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 571 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 13755 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 9858 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 7547 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Oil Filter Adapter Replacement Oil Filter Adapter: Service and Repair Oil Filter Adapter Replacement Oil Filter Adapter Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the oil pan drain plug and drain the oil into a suitable container. 3. Remove the oil filter. 4. Remove the oil filter adapter. Installation Procedure Notice: Refer to Fastener Notice. 1. Install the oil pan drain plug into the drain pan. Tighten the plug to 25 N.m (18 lb ft). Campaign - Possible Air-Bag Deployment/Servce Light ON Technical Service Bulletin # 09184A Date: 091026 Campaign - Possible Air-Bag Deployment/Servce Light ON CUSTOMER SATISFACTION Bulletin No.: 09184A Date: October 26, 2009 Subject: 09184A - Material Over Sensing and Diagnostic Module Retaining Moisture Models: 2007-2009 Chevrolet Silverado 2007-2009 GMC Sierra Currently or Previously Registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, , West Virginia, Wisconsin Supercede: This bulletin has been revised to include an inspection procedure and a new labor code. Vehicles with vinyl flooring and no cutout flap require no repair. All technicians are to review the new inspection procedure immediately. Please discard all copies of bulletin 09184, issued October 2009. Condition Certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. The vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Correction Dealers are to remove the acoustical pad above the SDM. Vehicles Involved Involved are certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin, and built within these VIN breakpoints: Page 21553 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 1740 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Page 1146 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 10537 Page 11744 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 15931 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 13827 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 14744 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 16080 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 24673 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20415 Circuit #742 for Auxiliary Power at the 7-way trailer connector is no longer connected by the GM Assembly Plant. If the customer desires auxiliary power at the trailer connector location (i.e. refrigeration, battery charger or interior light in the trailer), complete the following steps to connect circuit #742: 1. Locate the red/black wire, looped and taped to the chassis harness, below the brake master cylinder. 2. Break the tape and route the wire to the front of the underhood electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 3. Place the terminal on the smaller of the two studs on the electrical center and secure with an M6 fastener. This is circuit #742 to stud #1 for auxiliary power to the 7-way trailer connector. 4. ONLY for vehicles without RPO TP2 - Auxiliary Battery, install a 40 amp fuse to power the circuit. Important For vehicles equipped with RPO TP2 - Devices powered by this fuse will drain the vehicle battery if left connected with the vehicle not running. Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 3413 Important: Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation. 1. Install a new a O-ring on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. 2. Install the new speed sensor (2) into the speed sensor bore. Align the hole in the retaining bracket with the bolt hole in the speed sensor boss. Notice: Refer to Fastener Notice. 3. Install the speed sensor bolt (1). Tighten bolt to 12 N.m (108 lb in). 4. Reconnect the external wiring harness to the speed sensor. Page 7367 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2200 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 3167 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 5396 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 19102 Air Bag Deactivation Switch: Diagrams Inflatable Restraint I/P Module Disable Switch (C99) A/C - Compressor/Serpentine Belt Noise Drive Belt: Customer Interest A/C - Compressor/Serpentine Belt Noise TECHNICAL Bulletin No.: 07-01-38-010A Date: October 06, 2009 Subject: Air Conditioning (A/C) Compressor and/or Serpentine Belt Noise at Vehicle Start-up (Reprogram Powertrain Control Module (PCM)) Models: 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon Models Equipped With Air Conditioning (RPOs CJ2 or CJ3) Supercede: This bulletin is being revised to update the Condition and Correction information. Please discard Corporate Bulletin Number 07-01-38-010 (Section 01 - HVAC). Condition Some customers may comment on air conditioning (A/C) compressor slugging and/or serpentine belt or pulley rattle noise at vehicle start-up in warmer outside ambient temperature conditions. Others may describe the noise as a belt chirp or as a thumping/grinding noise coming from the A/C compressor at vehicle start-up. Cause This condition may be caused by the A/C compressor trying to move liquid refrigerant through the system. Correction - A revised PCM calibration has been released to address this condition. Reprogram the PCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. - When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. - When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. - During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information Note *Please use Failure Code 93 for any warranty claims submitted using this bulletin. For vehicles repaired under warranty, use the table above. Restraints - Air Bag Readiness Light On. Parking Brake Cable: Customer Interest Restraints - Air Bag Readiness Light On. TECHNICAL Bulletin No.: 09-09-41-005 Date: June 26, 2009 Subject: Air Bag Readiness Light On, Service Air Bag Message, Inflatable Restraint Sensing and Diagnostic Module (SDM) Corrosion (Replace SDM/Cut and Remove Carpet Pad) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the Air Bag Readiness Light is on. There may also be a Service Air Bag Message on the Driver Information Center (DIC). Upon further investigation, the Sensing and Diagnostic Module (SDM) may be corroded. Cause This condition may be caused by an unseated parking brake cable grommet causing water intrusion under the carpet or vinyl floor, resulting in wet padding. Power washing the vinyl floor and/or customer snow boots can introduce water to the padding above the SDM area. As the padding gets wet, water wicks through the padding towards the SDM over time. Over an extended period of time of constant exposure to water with potential salt/calcium and other elements, the SDM surface starts to corrode. Correction 1. Replace the SDM per SI procedures. Refer to Inflatable Restraint Sensing and Diagnostic Module Replacement in SI. 2. Inspect the SDM connector for corrosion. If corrosion is evident, repair or replace the connector. Refer to SIR/SRS Wiring Repairs in SI. 3. Verify the parking brake cable grommet is sealed properly. Important Cut and remove the padding from around the SDM as instructed whenever the SDM is serviced even if no corrosion is evident to prevent future moisture and corrosion to the SDM and connector. 4. Cut and remove padding from the area around and above the SDM. Refer to illustration above. Make an addition cut to remove all of the padding above the SDM. Parts Information Refer to Group Number 16.712 (Inflatable Restraint System) of the GM Parts Catalog for the appropriate service parts. Warranty Information For vehicles repaired under warranty, use the table above. Page 2034 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 21151 4. Apply 3M Automotive Adhesion Promoter 06396, or equivalent, to the underside of the reveal molding seals. Tip An approximate 600 mm (24 in) length of tape should allow for overlap at the top to be trimmed back leaving a tail of release liner (1) and, at minimum, should reach the fender cut line at the bottom. 5. Apply a 600 mm (24 in) length of 3M Automotive Acrylic Plus Attachment Tape 06386 (1.14 mm (0.045 in) thick x 6.35 mm (0.25 in) wide), or equivalent, to both sides of the windshield. Ensure the tape (1) position is centered between the windshield edge (2) and the tape/grease pencil line (3). Do not remove the release lining from the tape yet. 6. Reinstall the reveal molding to one side by sliding the molding downward and ensuring that the top lip is engaged at the upper edge of the windshield. Body - Vehicle Glass Distortion Information Front Door Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Body - Outside Door Handle(s) Squeak When Operated Front Door Exterior Handle: Customer Interest Body - Outside Door Handle(s) Squeak When Operated TECHNICAL Bulletin No.: 08-08-64-007 Date: May 13, 2008 Subject: Squeaky Outside Door Handle (Grease U-Channel of Handle) Models: 2007-2008 Cadillac Escalade, Escalade EXT, Escalade ESV 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Condition Some customers may comment on a squeak noise coming from the door handle as the handle is actuated. Cause This condition may be caused by the pin and the inside of pawl surface making contact with each other, resulting in a squeak noise. Correction DO NOT REPLACE THE DOOR HANDLE. 1. Remove the fasteners to the door handle, leaving the rod to the latch attached. 2. Apply a generous amount of dielectric silicone grease, P/N 12345579 (in Canada, 10953481), as shown in the graphics, into the U-channel of the handle between the pawl and the tower where the gray pin enters through the spring and the pawl. 3. Cycle the handle at least 20 times to work the grease around the pin and to make sure that the squeak has been eliminated. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7146 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 5723 Body Control Module: Service and Repair Body Control Module Replacement Body Control Module Replacement Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 14838 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 18366 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 10909 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Fuel Tank Pressure Sensor Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 13035 Torque Converter Clutch Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 6L50/6L80/6L90 - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Page 22498 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Service and Repair Child Seat: Service and Repair Child Seat Restraint System Belt Bracket Replacement (Ext Cab/Crew Cab) Front Seat Belt Buckle Replacement Seat Belt Buckle: Service and Repair Front Seat Belt Buckle Replacement Front Seat Belt Buckle Replacement Page 1373 Driver Door Switch (DDS) X7 (AN3/DL3) Page 1280 Control Module: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Control Module Replacement Page 16725 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 19682 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Page 12695 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 4560 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 11109 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 3901 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 11669 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 20055 Radio Rear Side Door Speaker Replacement (Crew Cab) Radio Rear Side Door Speaker Replacement (Crew Cab) Page 4753 5. Remove engine wire harness clip (1) from front cover. 6. Disconnect the crankshaft position (CKP) sensor electrical connector (2). 7. Remove the CKP sensor bolt and sensor. Page 16480 X305 Body Harness to Passenger Seat Harness (-AN3) Page 5183 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 17266 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Page 8352 Data Link Connector (DLC) Page 3754 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Page 3410 Transmission Speed Sensor: Diagrams 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Internal Connector End Views Input and Output Speed Sensor (ISS/OSS) Page 5109 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 13988 Allison - Automatic Transmission Control Module: Service and Repair Allison - Automatic Transmission Transmission Control Module Replacement Page 7185 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (7) from the camshaft position (CMP) sensor wiring harness jumper. 2. Remove the water pump. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor and wiring harness jumper from the engine front cover. 5. Disconnect the CMP sensor wiring harness jumper from the CMP sensor. 6. Remove the CMP sensor from the wiring harness jumper. Installation Procedure Page 11346 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (7) from the camshaft position (CMP) sensor wiring harness jumper. 2. Remove the water pump. 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor and wiring harness jumper from the engine front cover. 5. Disconnect the CMP sensor wiring harness jumper from the CMP sensor. 6. Remove the CMP sensor from the wiring harness jumper. Installation Procedure Page 5107 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 19613 Memory Seat Module X3 (AN3) Page 7498 HISTORY DTC If all readings are normal per Step 2 above, capture and record Freeze Frame/Failure Data, clear DTCs and attempt to duplicate the fail conditions. 1. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of "HLLL" and the IMS state of "Neutral/Drive 6", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM or low value, Engine Torque >30 Nm. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Determine if the shift lever can be hung-up between Neutral and Drive 6. If so, there may be excessive drag in the system. - Move the shift lever through each detent position, ensuring positive detent feel. If any concern is noted, remove the transmission oil pan and repeat the shift lever movement. Ensure that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. If the vehicle has been returned to the dealer with this Freeze Frame bit codes after repairs, contact the person(s) below in Step 4. 2. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHLH" and IMS state of "Blank", complete the following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS >0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 3. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of "HHHL" and IMS state of "Invalid", complete the Locations Impact Sensor: Locations SIR Component Views Front Sensors +10 Series 1 - Hood 2 - Inflatable Restraint Front Sensor - Left 3 - Inflatable Restraint Front Sensor - Right Left Front of the Engine Compartment (-10 Series) OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 15763 7. Install the mega fuse cover. 8. Install the positive battery cable connector (1) to the UBEC. Page 7660 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.3L) Removal Procedure 1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Page 1590 lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If re-installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. Notice: Refer to Fastener Notice. 2. Install the ECT sensor to the cylinder head. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 10776 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 23723 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 23848 Close the passenger door. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4523 Notice: Refer to Fastener Notice. 4. Install the rocker arm cover bolts. Tighten the bolts to 12 N.m (106 lb in). 5. Position the engine wiring harness. 6. Connect the engine wiring harness clips. 7. Connect the following electrical connectors: * The ignition coil (1) * The ignition coil drive (2) * The generator (3) 8. Position the heater hoses. 9. Install the heater outlet to the hose clip. Page 21468 Passenger Assist Handle: Service and Repair Front Assist Handle Replacement Front Assist Handle Replacement Page 3674 Page 11282 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 9667 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 7162 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 5574 Disclaimer Page 20836 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. Page 14614 1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. 2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. Important: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary. 3. Install the PNP switch bolts finger tight. 4. Install J 41364-A onto the PNP switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool. Notice: Refer to Fastener Notice. 5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts to 25 N.m (18 lb ft). 6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time. 7. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to 25 N.m (18 lb ft). Page 16664 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Campaign - Roof Lighting Circuit Addition Spot Lamp: All Technical Service Bulletins Campaign - Roof Lighting Circuit Addition Subject: Service Update for Inventory and Customer Vehicles-Missing Circuit for Optional Roof Mounted Light (Beacon)-Expires with Base Warranty # 07029 - (01/29/2007) Models: 2007 Chevrolet Silverado 1500 2007 GMC Sierra 1500 with Optional Roof Mounted Light (TRW & -YE9) THIS SERVICE UPDATE INCLUDES VEHICLES IN DEALER INVENTORY AND CUSTOMER VEHICLES THAT RETURN FOR ANY TYPE OF SERVICE AND WILL EXPIRE AT THE END OF THE INVOLVED VEHICLE'S NEW VEHICLE LIMITED WARRANTY PERIOD. Purpose This bulletin provides a service procedure to create a circuit for the optional roof mounted light on certain 2007 Chevrolet Silverado 1500 and GMC Sierra 1500 vehicles equipped with provisions for an optional roof mounted light (TRW & -YE9). On these vehicles, the circuit for the operation roof mounted light is missing. This service procedure should he completed as soon as possible on involved vehicles currently in dealer inventory and customer vehicles that return to the dealer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Parts Information Parts required to complete this service update are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Service Procedure Tools Required J 38125 Terminal Repair Kit Page 10996 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 23025 ECM Inhibit - The ECM detects a RAM corruption associated to the cruise control system. ECT Overtemp - The ECM detects the engine temperature is above the calibrated threshold. Engine Run Time - The ECM detects that the cruise control system has been requested and the engine run time counter is not active. Engine Speed - The ECM detects that the engine speed is less than or greater than a calibrated RPM. First Gear - While the cruise control system is active, the ECM detects that the transmission is in Drive 1. High Speed - The ECM detects that the vehicle speed is greater than the calibrated amount. High Voltage - The ECM detects that the ignition voltage is above 16 volts. Illegal Mode - The ECM detects that the acceleration mode is active without the activation of the Accel. switch. Lost Fwd Gear - The ECM detects that transmission is in Neutral, Reverse or Park. Low Speed - The ECM detects that the vehicle speed is less than 37 km/h (23 mph) while the cruise control system was enabled. Low Voltage - The ECM detects that the ignition voltage is below 9 volts. Memory DTC - The ECM detects an internal memory fault. MPH Limit - The ECM detects the vehicle is over speed and that the fuel shutoff has been activated. None - This parameter is displayed when a new ECM has been installed. Over Set Speed - The ECM detects the current vehicle speed is greater than the set vehicle speed by more than a calibrated amount. Park Brake - ECM detects the park brake switch is active. Pedal Initialize - The ECM detects that a stop lamp pedal activation had not occurred before the cruise control system was requested. PTO Active - The ECM detects power take off is active. RPM Limit - The ECM detects the engine is over speed and that the fuel shutoff has been activated. S/C On - Speed High - The ECM detects the Set/Coast switch is briefly applied while the current vehicle speed is greater than the set vehicle speed by more than a calibrated amount. Simul SC/RA Sw - The ECM detects that the Set/Coast switch and the Resume/Accel switch are active at the same time. Sw Invalid Page 14005 Inspection Procedure Using the exploded views in this bulletin, inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. If a valve is restricted and cannot be corrected by cleaning the valve and bore, then replace the valve body. Describe the restricted valve on the repair order. Page 12956 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 24719 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 9243 Camshaft Position Sensor: Service Precautions Camshaft Position Actuator Removal and Installation Caution Caution: Do not push or pull on the reluctor wheel of the camshaft position (CMP) actuator during removal or installation. The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins. Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator. The actuator return spring is under tension and may rotate the dislodged reluctor wheel, causing personal injury. Page 12656 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 13845 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 7373 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7942 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Specifications Brake Fluid: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme 11 Brake Fluid or equivalent DOT-3 brake fluid. Page 7914 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 11627 2. Connect the engine wiring harness electrical connector (1) to the knock sensor. 3. Position the knock sensor sleeve (3) up and over the knock sensor. 4. If equipped, position the oil pan skid plate and install the bolts. Tighten the bolts to 28 N.m (21 lb ft). 5. Lower the vehicle. Page 10451 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 6908 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 16736 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 10025 Extended Cab Short Box Shown Below, Other Configurations Similar 6. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 7. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 8. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 9. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 10. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 11. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 12. Raise the transmission and reinstall the transmission support. 13. Connect the EVAP canister vent valve electrical connector. 14. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 15. Lower the vehicle. Correction (2007-2010 New Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the EVAP canister vent valve assembly and relocate the remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. Use Service Kit P/N 19207763 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. Page 11122 1. Install a NEW throttle body gasket into the upper intake manifold. 2. Place the throttle body onto the upper intake manifold. Notice: Refer to Fastener Notice. 3. Install the throttle body bolts. Tighten the bolts to 10 N.m (89 lb in). 4. Connect the engine wiring harness electrical connector (2) to the throttle body. 5. Install the air cleaner outlet resonator. Page 12645 Page 24089 Turn Signal Switch: Service and Repair Turn Signal Switch Cancel Cam Position Plate Replacement Turn Signal Switch Cancel Cam Position Plate Replacement Tools Required * J 23653-SIR Steering Column Lock Plate Compressor * J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Remove the inflatable restraint steering wheel module coil and the inflatable restraint steering wheel module coil wave washer. Important: DISCARD the old steering shaft lock plate ring. 2. Remove the following parts from the steering shaft: 1. Steering shaft lock plate retaining ring (1) using compressor J 23653-SIR and adapter J 42137. 2. Turn signal switch cancel cam position plate (2) 3. Turn signal switch cancel cam (3) Installation Procedure Page 17130 Page 4568 Step 17 - Step 20 Body - Front Door Window Regulator Squeak Noise Front Door Window Glass: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 22203 Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Front Center Seat Back Cushion Latch Upper Cover Replacement (AE7) Body Controls - Unable To Reprogram Body Control Module Body Control Module: All Technical Service Bulletins Body Controls - Unable To Reprogram Body Control Module INFORMATION Bulletin No.: 09-08-47-001A Date: June 14, 2010 Subject: Unable to Reprogram Body Control Module (BCM), BCM Reprogramming Did Not Complete - Revised Reprogramming Instructions Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2008-2010 Cadillac CTS 2010 Cadillac CTS Wagon 2010 Chevrolet Camaro 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Equinox, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2008-2010 GMC Savana 2010 GMC Terrain 2007-2009 Pontiac Torrent 2008-2009 Pontiac G8 2008-2009 HUMMER H2 2007-2009 Saturn OUTLOOK 2008-2009 Saturn VUE Refer to GMVIS Supercede: This bulletin is being revised to update the models and the model years. Please discard Corporate Bulletin Number 09-08-47-001 (Section 08 - Body and Accessories). Some technicians may experience an unsuccessful body control module (BCM) reprogramming event, when choosing the Reprogram ECU selection on the Service Programming System (SPS). The technician may also notice that when attempting to reprogram the BCM again after this incident has occurred, the BCM may not complete the programming event. This condition may be caused by the following: - A reprogramming event that was interrupted due to a lack of communication between the vehicle and the TIS2WEB terminal. - The vehicle experienced low system voltage during the reprogramming event. Important Do not replace the BCM for this condition. SPS Programming Process Selection Perform this procedure first. 1. If reprogramming has failed during the initial reprogramming event, back out of the SPS application completely. 2. Re-select SPS from the TIS2WEB terminal application. 3. When selecting the Programming Process , choose Replace and Program ECU , even though a new BCM is NOT being installed. 4. Reprogram the BCM using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the SPS procedures in SI. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. Page 7412 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 22241 For vehicles repaired under warranty, use the table above. Disclaimer Page 6808 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 7855 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 6695 4. Connect the engine wiring harness electrical connector (1) to the HO2S pigtail electrical connector. 5. Connect the CPA retainer. 6. Lower the vehicle. Page 15948 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 2096 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Service and Repair Stabilizer Bushing: Service and Repair Stabilizer Shaft Insulator Replacement (1500) Locations Data Link Connector: Locations Data Communication Component Views Below the Driver Knee Bolster 1 - I/P Trim 2 - Instrument Panel Cluster 3 - Data Link Connector (DLC) Page 17590 Alignment: Testing and Inspection Trim Height Inspection Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can the vehicle to cause bottom out over bumps, damage to the suspension components, and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Set the tire pressures to the pressure shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label. * Check the fuel level. Add additional weight if necessary to simulate a full tank of gas. (One U.S. gallon of gasoline weights approximate 6.5 lbs. One liter of gasoline weights 0.70 kg) * Make sure the passenger and rear compartments are empty, except for the spare tire. * Make sure the vehicle is on a level surface, such as an alignment rack. * For vehicles equipped with automatic level control, make sure that the system is functioning properly. * Make sure that all doors, lift gate/trunk and the hood are securely closed. * Check for installed after market accessories or modifications that could affect trim height measurements: - Larger or smaller than production wheels and tires - Lifting or lowering kits - Wheel opening flares - Ground affects * Remove the alignment rack floating pins. Measuring the Z Height Important: For vehicles equipped with torsion bars, the Z height must be verified before the alignment. The Z height dimension measurement determines the proper ride height for the front end of the vehicle. Vehicles equipped with torsion bars use a adjusting arm in order to adjust the Z height dimension. Vehicles without torsion bars have no adjustment and could require replacement of suspension components. Important: All dimensions are measured vertical to ground. Cross vehicle Z heights should be within 12 mm (0.47 in) to be considered correct. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4L60-E/4L65-E/4L70-E - Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Valve Body and Pressure Switch Replacement Removal Procedure 1. Ensure that removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission: * The torque converter clutch solenoid (1) * The pressure control solenoid (2) * The internal wiring harness (3) * The 2-3 shift solenoid (4) * The 1-2 shift solenoid (5) * The transmission fluid pressure manual valve position switch (6) * The 3-2 shift solenoid (7) * The torque converter clutch pulse width modulation (TCC PWM) solenoid (8) 2. Remove the fluid level indicator. 3. Remove the transmission filter. 4. Disconnect the internal wiring harness electrical connectors from the following components: * The transmission fluid pressure manual valve position switch (1) * The 1-2 shift solenoid (2) * The 2-3 shift solenoid (3) * The pressure control solenoid (4) * The TCC PWM solenoid (5) * The 3-2 shift solenoid (6) Service and Repair Balance Shaft: Service and Repair Balance Shaft Replacement Tools Required * J 8092 Universal Driver Handle * J 36996 Balance Shaft Installer * J 45059 Angle Meter Removal Procedure 1. Remove the radiator. 2. Remove the air conditioning (A/C) condenser. 3. Remove the lifter pushrod guide. 4. Remove the timing chain and camshaft sprocket. 5. Remove the balance shaft drive gear. 6. Remove the balance shaft driven gear bolt. 1. Use a wrench in order to secure the balance shaft. Place the wrench onto the balance shaft near to the balance shaft front bearing. 2. Remove the balance shaft bolt. 3. Remove the wrench from the balance shaft. 7. Remove the balance shaft driven gear. Page 8285 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 9698 Page 11052 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 2418 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 9640 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 15892 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 24158 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Electrical Symbols Electrical Symbols Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Page 18839 Disclaimer Page 4373 Page 6444 Page 6469 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2226 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 6083 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16040 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 5023 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 24101 10. Twist the end of circuit 3040 together with circuit 240. Connect the circuits from the side of the circuit that does not have a terminal. Important: Apply heat to sleeve using a hot air gun or Ultratorch. Apply heat to the center of the sleeve and continue heating for a minimum of 30 seconds. Once the glue starts to melt, slowly rotate the sleeve while applying heat evenly until hot glue is visible outside the sleeve. 11. Using a BLUE colored crimp and seal splice sleeve PN 12089190, crimp the 240/3040 end to the 3040 end. Refer to Splicing Copper Wire Using Splice sleeves in SI, if required. 12. Re-apply tape (1) to the harness. 13. Plug the 40-way connector X1 back into the backside of the LBEC. 14. Verify that there is power to the beacon switch by activating the switch. If the beacon switch light indicator illuminates when the switch is in the ON position and turns off when the switch is in the OFF position, the repair has been performed correctly. 15. Install the instrument panel (I/P) knee bolster. Refer to Knee Bolster Replacement in SI. 16. Install the park brake release handle. Refer to Park Brake Release Handle Assembly Replacement in SI. Claim Information For vehicles repaired under this service update, use the table. A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 16785 Page 15231 6. Position a piece of wood across the piston to be installed. 7. Applying equal pressure by hand while pushing down, install the piston in the bore. 8. Remove the piece of wood. Notice: Refer to Fastener Notice. 9. Install the bleeder valve in the brake caliper housing. Tighten the bleeder valve to 12 N.m (106 lb in). 10. Install the bleeder valve cap. 11. Install the brake caliper. Page 17139 Junction Block - Left I/P, Bottom View Page 5815 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 20375 Trailer Brake Control Module: Service and Repair Trailer Brake Control Module Replacement Trailer Brake Control Module Replacement Page 15230 4. Install the boot over the end of the piston so the fold will face toward the brake caliper housing piston bore opening. Important: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 24186 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 212 View of the connector when released from the component. View of another type of Micro 64 connector. Page 10108 11. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 12. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. 14. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. 15. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 16. Unclip the inline harness connector from the bracket. 17. Remove the fuel line bracket bolt (1). 18. Remove the fuel/EVAP line clip nut (2). 19. Loosen the brake pressure modulator valve (BPMV) bolts. Slide the BPMV off of the frame and reposition the BPMV without disconnecting the brake lines. 20. Unclip the line assembly from the frame. 21. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Body - Side Door Body Mounted Weatherstrip Replacement Rear Door Weatherstrip: All Technical Service Bulletins Body - Side Door Body Mounted Weatherstrip Replacement INFORMATION Bulletin No.: 09-08-64-012C Date: November 22, 2010 Subject: Information on Side Door Body Mounted Primary Weatherstrip Replacement Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to communicate feedback received from engineering information and add the 2011 model year. Please discard Corporate Bulletin Number 09-08-64-012B (Section 08 - Body and Accessories). Some customers may comment about side door wind noise, water leaks or door fit concerns. These concerns may appear to be related to the body mounted primary door opening weatherstrips. As a result of feedback received from engineering information, we have found that many replacements of the primary door opening weatherstrip are for issues not related to the primary door opening weatherstrip. The instructions below are a guide to help "root cause" the customer's concern and obtain the proper direction for repair. Recommendation Note: If the seal is properly installed, it will not cause a Windnoise. If mis-installed, the seal could create a Windnoise that can be corrected by re-installing the seal. If the condition is for Windnoise, please view the training courses on this subject and follow the proper diagnostics outlined in courses 10210.01D 2010 SKH Seminar Jan Emerging Issues,.02D (Feb),.03D (March) (3 Parts) (Emerging Issues programs available to U.S. dealers only). If the condition is specific to an itch noise, refer to Corporate Bulletin Number 06-08-64-035F to correct that concern. If diagnosing a water leak, please follow information supplied in Corporate Bulletin Number 09-08-57-002B. For door fit concerns, or if the seal is loose or exhibits a poor appearance, inspect for even retention around the door. If the seal pulls off too easily, the channel crimp may be wide/loose as shown between the dashed lines in the graphic above. Page 2868 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: All Technical Service Bulletins Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Page 9801 Page 7252 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. TRLR RT STOP/TURN PCB Relay Brake Lamp Relay: Locations TRLR RT STOP/TURN PCB Relay Electrical Center Identification Views Fuse Block - Underhood, Label Page 9047 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 5513 Catalytic Converter: Service and Repair Catalytic Converter Replacement (4.3L) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the oil pan skid plate bolts and skid plate, if equipped. 3. Remove the transmission crossmember. 4. Remove the right front connector position assurance (CPA) retainer. 5. Disconnect the right front heated oxygen sensor (HO2S) electrical connector (5) from the engine wiring harness electrical connector (4). 6. Remove the right rear CPA retainer. 7. Disconnect the engine wiring harness electrical connector (2) from the right rear HO2S electrical connector (1). 8. Remove the right rear HO2S electrical connector clip from the engine harness clip (3). Page 10563 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 21634 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 3510 1. Install the air cleaner outlet resonator to the MAF/IAT sensor and throttle body. Notice: Refer to Fastener Notice. 2. Tighten the air cleaner outlet resonator clamp (2) at the throttle body. Tighten the clamp to 4 N.m (35 lb in). 3. Tighten the air cleaner outlet resonator clamp (1) at the MAF/IAT sensor. Tighten the clamp to 4 N.m (35 lb in). 4. Connect the PCV hose (1) to the air cleaner outlet resonator. Page 13816 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 22736 Tailgate Release Handle: Service and Repair Endgate Linkage Replacement (Pickup Box) Endgate Linkage Replacement (Pickup Box) Page 402 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Fuse Block - I/P, Top View Power Door Lock Relay: Locations Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Label Page 2050 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 17123 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 15216 Page 11027 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 22077 3. Inspect the wiring harness for damage or improper routing near drivers side rear screw hole. Refer to the above graphic (callout # 1 shows proper routing callout # 2 indicates improper routing). 4. Repair the wiring harness as necessary. If the wiring harness is not damaged refer to SI for diagnosis and repair of the system. 5. Install the DVD screen and the four retaining screws. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8496 Knock Sensor: Service and Repair Knock Sensor 2 Replacement Knock Sensor 2 Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Reposition the knock sensor sleeve (3) down, away from the knock sensor. 4. Disconnect the engine wiring harness electrical connector (1) from the knock sensor. Page 5031 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 5287 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 11644 Page 16449 X123 X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Page 7381 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Diagrams Cellular Phone Microphone: Diagrams Entertainment/Communication Connector End Views Cellular Microphone (UE1/U3U/UVB) Front Wheelhouse Liner Replacement - Left Side Front Fender Liner: Service and Repair Front Wheelhouse Liner Replacement - Left Side Front Wheelhouse Liner Replacement - Left Side (Chevrolet) Page 16687 Vehicle Zoning Strategy Truck Zoning Page 3298 13. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 14. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 15. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 16. Install the connector to the sensor. 17. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 18. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Important: If reusing the existing sensor, you must align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. If the new sensor did not come with a pin installed, you must reorder a new sensor. 19. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 20. Install the connector to the sensor. Page 23861 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 24249 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 4125 Junction Block - Left I/P X2 (Pin A1 To E2) Page 15863 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 3165 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 4519 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement - Right Side Valve Rocker Arm Cover Replacement - Right Side Removal Procedure 1. Loosen the air cleaner outlet duct clamp at the mass airflow (MAF)/intake air temperature (IAT) sensor. 2. Remove the positive crankcase ventilation (PCV) hose. Page 3003 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Interior - Poor Carpet/Rubber Mat Fit/Loose/Bulging Carpet: Customer Interest Interior - Poor Carpet/Rubber Mat Fit/Loose/Bulging Bulletin No.: 07-08-110-007B Date: November 30, 2007 TECHNICAL Subject: Front Floor Carpet or Rubber Floor Covering Poor Fit, Loose or Bulging (Install Floor Insulator/Deadener) Models: 2007-2008 Chevrolet Silverado Regular Cab 2007-2008 GMC Sierra Regular Cab with Carpet (RPO B30) or Rubber (RPO BG9) Floor Covering Supercede: This bulletin is being revised to add the 2008 model year. Please discard Corporate Bulletin Number 07-08-110-007A (Section 08 - Body and Accessories). Condition Some customers may comment on the way the front floor carpet or rubber floor covering (1) fits on the center of the floor tunnel. Others may comment that the floor covering is loose, bulging or just fits poorly on the passenger side. Cause This condition may be caused by a lack of padding under the front floor carpet or rubber floor covering. Correction Install floor insulator/deadener to the top of the floor tunnel using the steps below. For vehicles equipped with a manual 4 x 4 shifter, the shifter knob and trim plate will need to be removed. Refer to Transfer Case Control Lever Replacement in SI. Remove the carpet or rubber floor covering away from the front floor tunnel. Refer to Floor Panel Carpet Replacement (Regular Cab) in SI. Tip The instrument panel (IP) support bracket will need to be removed by prying apart the two trim panels and removing the bolts. Page 11647 Vehicle Zoning Strategy Truck Zoning Page 5348 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 22183 Power Seat Switch: Service and Repair Power Seat Switch Replacement Power Seat Switch Replacement Page 5755 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 13321 Pressure Regulating Solenoid: Service and Repair Control and Shift Solenoids Replacement Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 20723 Page 16185 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 2503 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 12206 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 8129 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 16020 Fuse Block - I/P, Top View Electrical Center Identification Views Fuse Block - I/P, Label Page 6750 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 27 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 6285 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 10293 Fuel: Technical Service Bulletins Fuel System - E85 Refueling Station Information Bulletin No.: 06-06-04-030 Date: May 15, 2006 INFORMATION Subject: Locations of E85 Refueling Stations and Expanded E85 Information Models: 2007 and Prior GM Cars and Trucks Equipped for Flexible Fuel (E85) Attention: U.S. dealers - This bulletin should be directed to the Sales Manager as well as the Service Manager. Copies of this bulletin may be given to customers purchasing or considering the purchase of E85 capable vehicles, and may be left or posted in customer waiting areas. Canadian dealers - This bulletin is intended for the U.S. Market and provides only limited information relevant to the Canadian market. Customer Questions, Concerns and Refueling Locations for E85 Fuel Extensive information on E85 Ethanol based fuels can be found at www.livegreengoyellow.com . This General Motors site contains vital information that anticipates and answers customer questions and concerns about E85 fuel. Part of the information is a useful link that provides the location nationally of all E85 refueling stations. Disclaimer Interior - Lint Accumulation On Ebony Colored Seats Seat Cover: Customer Interest Interior - Lint Accumulation On Ebony Colored Seats TECHNICAL Bulletin No.: 07-08-50-018E Date: August 05, 2009 Subject: Excessive Lint Accumulation on Ebony Colored Cloth Seats (Replace All Seat Covers, Headrests and Armrests) Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL Built Prior to October 1, 2008 and Equipped with Ebony Cloth Seats (RPO 19C and 19D) Supercede: This bulletin is being revised to update the parts information for the utilities. Please discard Corporate Bulletin Number 07-08-50-018D (Section 08 - Body and Accessories). Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Condition Some customers may comment on excessive lint accumulation on the cloth seat material. Darker colored seat fabric seems to show the condition more than lighter fabrics. Cause The source of the lint accumulation is not the seat fabric material. The seat material, though, exhibits a tendency to accumulate and retain lint from sources that come into contact with the fabric. Correction Important All seats will need to be updated in the vehicle. Let customers with RPO 19D know that the appearance of the insert material will be noticeably different. If the customer has ebony colored cloth seats, replace the seat covers (back and cushion), the headrests and the armrests with revised fabric. Refer to SI for the appropriate seat back and cushion cover, headrest and armrest replacement procedures. Parts Information Page 15923 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 3987 Page 18791 Impact Sensor: Service and Repair Inflatable Restraint Vehicle Rollover Sensor Replacement Inflatable Restraint Vehicle Rollover Sensor Replacement Page 2372 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 2180 Intake Air Temperature Sensor: Diagrams Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 8617 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 709 19 - Transfer Case Shift Control Switch (NQF/NQH) 20 - Turn Signal Multifunction Switch Interior HVAC Module 1 - Air Temperature Actuator 2 - Recirculation Actuator (C67) 3 - Blower Motor 4 - Blower Motor Control Module 5 - Mode Actuator Page 15925 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 5210 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Controls Component Viewst Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Page 2379 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 23639 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 22620 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement (with DL8 and without SLT) Page 2339 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 9389 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 8982 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 9065 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 5964 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 18230 Instrument Panel Center Air Outlet Replacement (With RPO SLT) Instrument Panel Center Air Outlet Replacement (With RPO SLT) Page 20804 Front Door Window Glass: By Symptom Technical Service Bulletin # 07-08-64-019C Date: 110408 Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Page 13748 Page 3928 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 15210 Page 12949 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13278 Disclaimer Page 12614 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 12795 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON, Engine OFF).................................................................................................. ..............................................345-414 kPa (50-60 psi) Page 6868 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 8180 3. Position the engine wiring harness lower electrical connector and engage the retainer (3) securing the lower connector (4) to the ECM. 4. Position the engine wiring harness upper electrical connector and engage the retainer (2) securing the upper connector (1) to the ECM. 5. Connect the negative battery cable. 6. If a NEW ECM was installed, program the ECM. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 2286 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 10404 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 2083 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 16368 DO NOT substitute with vinyl electrical tape or friction tape. Use only the tape specified above. 15. Tape the harness starting at the MSM connectors (1) extending back to the new break-out location (2) in the plastic carrier. 16. Install a plastic tie strap around the harness and the plastic carrier at the break-out point (1). 17. Install the new harness edge clip (1) 10 mm (0.4 in) further from the connectors and the existing harness clip. Ensure the clip is installed in the orientation shown. 18. Install the harness with the new harness clip in the location shown (1). Page 23868 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 2965 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 3908 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 14044 Page 5976 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 16688 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 17312 X219 Inline Harness Connector End Views X219 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Page 13188 Fluid Inspection Important: Transmission fluid must be changed whenever there is evidence of dirt or a high temperature condition. High temperature causes the transmission fluid to be discolored or to have a strong odor. Local conditions, severity of operation, or duty cycle may require more or less frequent fluid or filter change intervals. 1. Examine the drained fluid for evidence of dirt. Important: Cooler water may be contaminated by engine oil if an engine oil cooler is present; be sure to locate the correct source of cooler water contamination. 2. Examine the drained fluid for evidence of water. Obvious water contamination of the transmission fluid or transmission fluid in the cooling water from the heat exchanger indicates a leak between the water and fluid areas of the cooler. Inspect and pressure test the cooler to confirm the leak. Replace leaking coolers. Notice: Engine coolant in the transmission hydraulic system requires immediate action. Failure to clean or replace all contaminated components may result in premature transmission failure. 3. Examine the drained fluid for evidence of engine coolant. 4. Examine the drained fluid for evidence of metal. Metal particles in the fluid, other than minute particles normally trapped in the oil filter, indicate internal transmission damage. When this occurs, inspect the inside of the oil pan for excessive metal particles. Refer to Oil Pan Replacement. 5. Metal contamination requires complete transmission disassembly. Notice: Flush the transmission cooling system and inspect for restrictions following a transmission failure. Failure to repair or replace restricted oil cooling system components may result in premature transmission failure. 6. Clean all internal and external hydraulic circuits, cooler, and all other areas where the particles could lodge. Refer to Transmission Fluid Cooler Flushing and Flow Test. Page 15739 Tighten the nut to 9 N.m (80 lb in). 3. Position the ground strap to the rear of the left cylinder head. 4. Install the ground strap bolt. Tighten the bolt to 16 N.m (12 lb ft). Page 5981 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 707 Control Module HVAC: Locations HVAC - Manual HVAC Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 4216 Important: Snap Fit TPM sensors are still shipped in the OFF mode. However, the TPM no longer needs to be spun to remove it from the OFF mode. The sensor will exit its OFF state when the tire is inflated. The technician can then program the vehicle as normal. 3. Mount the tire to the rim. 4. Install the tire/wheel assembly on the vehicle. 5. Lower the vehicle. 6. Learn the tire pressure sensors. Page 3935 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 13189 Fluid - A/T: Testing and Inspection 4L60-E/4L65-E/4L70-E Transmission Fluid Checking Procedure Transmission Fluid Check This procedure checks the transmission fluid level, as well as the condition of the fluid itself. Notice: Always use the proper automatic transmission fluid listed. Using incorrect automatic transmission fluid may damage the vehicle. Before checking the fluid level, perform the following: 1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then, move the shift lever back to PARK (P). 4. Allow the engine to idle 500-800 RPM for at least 1 minute. Slowly release the brake pedal. 5. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center (DIC) or a scan tool. 6. Using the TFT reading, determine and perform the appropriate check procedure. If the TFT reading is not within the required temperature ranges, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. Cold Check Procedure Important: Use the cold check procedure only as a reference to determine if the transmission has enough fluid to be operated safely until a hot check procedure can be made. The hot check procedure is the most accurate method to check the fluid level. Perform the hot check procedure at the first opportunity. Use this cold check procedure to check fluid level when the TFT is between 27-32°C (80-90°F). 1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on the passenger's side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick tube all the way, wait three seconds and then pull it back out again. Important: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Keep the dipstick pointing down and check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection in this procedure. 6. If the fluid level is below the COLD check line, add only enough fluid as necessary to bring the level into the COLD line. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. 7. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. 8. Perform a hot check at the first opportunity after the transmission reaches a normal operating temperature between 82-93°C (180-200°F). Hot Check Procedure Important: Use this procedure to check the transmission fluid level when the TFT is between 82-93°C (180-200°F). The hot check procedure is the most accurate method to check the fluid level. The hot check should be performed at the first opportunity in order to verify the cold check. The fluid level rises as fluid temperature increases, so it is important to ensure the transmission temperature is within range. 1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on the passenger side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick tube all the way, wait three seconds and then pull it back out. Important: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Keep the dipstick tip pointing down and check both sides of the dipstick. Read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection. 6. A safe operating fluid level is within the HOT crosshatch band on the dipstick. If the fluid level is not within the HOT band, and the transmission temperature is between 82-93°C (180-200°F), add or drain fluid as necessary to bring the level into the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band. Important: To assist in reaching the correct temperature range of 82-93°C (180-200°F), drive the vehicle in second gear at no more than 65 mph until the desired temperature is reached. Page 15184 Yaw Rate Sensor: Diagrams Yaw Rate and Lateral Acceleration Sensor (JL4) Yaw Rate and Lateral Acceleration Sensor (JL4) Page 24723 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 22441 View of the connector when released from the component. View of another type of Micro 64 connector. Page 10722 Page 1800 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 13920 Transmission Position Switch/Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft Position Switch Replacement Page 12810 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Specifications Alternator: Specifications Generator Usage 145 Amp Generator (KG3) 145 Amp Generator (KG3) 160 Amp Generator (KW1) 160 Amp Generator (KW1) Page 11614 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 6801 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Restraints - Seat Belt Latch Stop Button Availability Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 16649 Install the lower B-pillar cover. Parts Information Warranty Information The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. Page 18589 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 1856 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 9619 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 22979 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 23464 4. Disconnect seat harness connectors (1) X1, X2, X3 and X4 from the MSM. 5. Identify connector X1. Refer to Component Connector End Views in SI. 6. Perform a terminal drag test on connector X1, paying special attention to terminals 1, 4, 6, 11 and 14. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Refer to Testing for Intermittent Conditions and Poor Connections in SI. 7. Replace any terminal in question including connector X1 terminals 1, 4, 6, 11 and 14 if necessary. Refer to Repairing Connector Terminals in SI. 8. Identify connector X4. Refer to Component Connector End Views in SI. 9. Perform the terminal drag test described in step 6, paying special attention to terminal 14. 10. Replace any terminal in question including connector X4 terminal 14 if necessary. Refer to Repairing Connector Terminals in SI. 11. Remove the harness clip (1) from the plastic carrier. 12. Cut the electrical tape holding the harness in the plastic carrier using a sharp utility knife in the area shown (1). 13. Free the harness from the carrier back to the area shown (1). 14. Obtain "*Woven Polyester (PET) Electrical Tape" (Special Order P/N RZ97156A00) from Kent Automotive. Refer to Parts Information below. Important Page 8556 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 21430 Glove Compartment: Service and Repair Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Instrument Panel Compartment Door Dampener Replacement (Without RPO SLT) Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools - J 35910 Drive Axle Seal Clamp Pliers - J 36652-1 Drive Axle Clamp Swage Tool - J 36652-98 Axle Swage Tool Disassemble Procedure 1. Remove the wheel drive shaft. Refer to Wheel Drive Shaft Replacement See: Service and Repair. Important: Use caution when removing the tripot housing (1). 2. Using the appropriate tool, remove the boot clamp (2). 3. Remove the tripot housing (1). Important: If using denatured alcohol or any other recommend cleaning solvent, allow the tripot housing to air dry. 4. Remove any grease from of the housing (1). 5. Using side cutters, remove the small boot retaining clamp (4). 6. Using the appropriate tool, remove the retaining ring (1), then the spider assembly (2), and the boot (3). 7. Using the appropriate tool, remove the any rust in the seal mounting area (grooves) (1). 8. If any of the internal components of the tripot assembly are found to be damaged or have excessive wear, replace the tripot as an assembly. Assemble Procedure Page 1983 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 14082 Valve Body: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Valve Lower Body and Upper Body Replacement Campaign - Possible Air-Bag Deployment/Servce Light ON Technical Service Bulletin # 09184A Date: 091026 Campaign - Possible Air-Bag Deployment/Servce Light ON CUSTOMER SATISFACTION Bulletin No.: 09184A Date: October 26, 2009 Subject: 09184A - Material Over Sensing and Diagnostic Module Retaining Moisture Models: 2007-2009 Chevrolet Silverado 2007-2009 GMC Sierra Currently or Previously Registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, , West Virginia, Wisconsin Supercede: This bulletin has been revised to include an inspection procedure and a new labor code. Vehicles with vinyl flooring and no cutout flap require no repair. All technicians are to review the new inspection procedure immediately. Please discard all copies of bulletin 09184, issued October 2009. Condition Certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. The vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Correction Dealers are to remove the acoustical pad above the SDM. Vehicles Involved Involved are certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin, and built within these VIN breakpoints: Page 22668 Sunroof / Moonroof Switch: Diagrams Sunroof Connector End Views Sunroof Switch A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Page 7214 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 14173 3. Install the pinion yoke. Align the marks made during removal. Notice: Refer to Pinion Flange/Yoke Installation Notice. 4. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 5. Install the washer and a new pinion nut. 6. Install the J 8614-01 onto the pinion yoke as shown. Notice: Refer to Fastener Notice. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 7. Tighten the pinion nut while holding the J 8614-01. Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. 8. Measure the rotating torque of the pinion. Compare this measurement with the rotating torque recorded during removal. Tighten the nut in small increments, as needed, until the rotating torque is 0.40-0.57 N.m (3- 5 lb in) greater than the rotating torque recorded during removal. 9. Once the specified torque is obtained, rotate the pinion several times to ensure the bearings have seated. Recheck the rotating torque and adjust if necessary. 10. Install the propeller shaft (3) to the pinion yoke (4). Page 6488 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 24208 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. A/T - MIL ON/DTC P0751 Is Stored In Memory Valve Body: All Technical Service Bulletins A/T - MIL ON/DTC P0751 Is Stored In Memory TECHNICAL Bulletin No.: 07-07-30-031D Date: February 20, 2009 Subject: Malfunction Indicator Lamp (MIL) On - Check Engine Light, DTC P0751 (Diagnose and Repair as Necessary) Models Supercede: This bulletin is being revised to provide additional information on the new spacer plate. Please discard Corporate Bulletin Number 07-07-30-031C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a malfunction indicator lamp (MIL) being illuminated. A scan tool may reveal DTC P0751 set in the TCM as current or in history. Correction Follow the service instructions below based on the group your vehicle is in. 2007 Silverado or Sierra with 6L90 Transmission (MYD) 1. Inspect and note the transmission fluid level and condition. If the level is high or low, it should be corrected and the vehicle road tested to verify that the condition is still present. 2. Remove the transmission bottom pan to inspect for possible debris. ^ If debris is found, the transmission should be disassembled to determine the source. Repair or replace the transmission in the most economical method following guidelines in Corporate Bulletin # 02-07-30-029. ^ If no debris is noted in the oil pan, remove the control valve body assembly and proceed to the next step. 3. Disassemble the valve body to: Page 453 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 2225 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Service and Repair Acceleration/Deceleration Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Page 3172 Knock Sensor: Description and Operation Knock Sensor (KS) System Description Purpose The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor (KS) system uses one or 2 flat response 2-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the control module through a low reference circuit. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Page 624 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Diagrams Oil Pressure Sender: Diagrams Displays and Gages Connector End Views Engine Oil Pressure (EOP) Sensor (Gas) Page 6634 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: All Technical Service Bulletins Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 13863 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Page 18547 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4375 The wheel hubs illustrated above are intended to provide enough visual details to identify subtle differences between the Gen II and Gen III replacement hubs. The various colors used in the graphics are not indicative of any difference or feature, but are used to increase the detail and clarity of the assembly. The associated part number is listed with each illustration. Please refer to the chart above for the specific application for each hub. Page 24499 Customer Notification - For US and Canada General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Recall Responsibility - For US and Export (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. Dealer Recall Responsibility - All All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. "An unattended (vehicle parked - key not in the "ON" position) under hood fire that can occur at any time and possibly involve nearby vehicles or structures." If the customer still refuses, provide the customer with a copy of the "Notice to Customer" document contained in this bulletin, record "customer declined recall repair" on the repair order and, if possible, have the customer sign the repair order. Retain this repair order at the dealership. Page 6268 Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. Remove the tire from the wheel. Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 3. Remove the tire pressure sensor nut. 4. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Page 3200 Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (Extended Cab +ASF) Page 6402 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Campaign - BCM Reprogramming for Battery Drain Body Control Module: All Technical Service Bulletins Campaign - BCM Reprogramming for Battery Drain Subject: Service Update for Inventory and Customer Vehicles-Battery Rundown-Expires with Base Warranty # 07033B - (02/15/2007) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED TO ADDRESS VEHICLES WITHOUT A DRIVER INFORMATION CENTER (DIC) AND POWER DOOR LOCKS/WINDOWS, AND A CONDITION WHERE THE ODOMETER READING DISPLAYS METRIC UNITS INSTEAD OF ENGLISH UNITS. DISCARD ALL COPIES OF BULLETIN 07033A, ISSUED FEBRUARY 2007. TECHNICANS MAY EXPERIENCE SLOW PERFORMANCE USING THE TIS2 WEB APPLICATION WHEN REPROGRAMMING THE VEHICLE TO CORRECT THE CONDITION TECHNICANS MAY NOTICE THE SLOWER APPLICATION PERFORMANCE FROM MID-MORNING UNTIL LATE AFTERNOON. TO ASSIST IN IMPROVED PERFORMANCE AND REDUCE PROGRAMMING TIME. IT IS RECOMMENDED TO COMPLETE THE BULLETIN PROCEDURE ON CUSTOMER VEHICLES FIRST. VEHICLES IN INVENTORY SHOULD BE PROGRAMMED DURING OFF PEAK HOURS IF SLOW PERFORMANCE IS EXPERIENCED. Purpose This bulletin provides a service procedure to reprogram the body control module (BCM). On these vehicles, and under certain conditions such as operating the radio with the engine off the battery can become discharged, preventing engine start-up. This service procedure should be completed as soon as possible on involved vehicles currently in dealer/retailer inventory and customer vehicles that return to the dealer/retailer for any type of service during the New Vehicle Limited Warranty coverage period. Vehicles Involved Page 9313 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 253 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 24147 Page 11767 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 7822 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 6968 Page 18161 Page 11832 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 22343 Page 17298 Multiple Junction Connector: Diagrams X200 - X299 X200 Inline Harness Connector End Views X200 Instrument Panel Harness to Body Harness X201 Inline Harness Connector End Views X201 Steering Column Harness to Instrument Panel Harness Service and Repair Differential Cover: Service and Repair Rear Axle Housing Cover and Gasket Replacement Removal Procedure 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Drain the rear axle. Refer to Rear Axle Lubricant Replacement (8.6 Inch Axle) Rear Axle Lubricant Replacement (9.5 LD Axle) Rear Axle Lubricant Replacement (9.5 Inch HD and 10.5 Inch Axles). 3. Remove the rear axle housing cover bolts (1). Discard the rear axle housing cover bolts. 4. Remove the rear axle housing cover (2) from the axle housing. 1. Catch the oil in a drain pan. 2. Remove any gasket material from the rear axle housing and/or the rear axle housing cover. Installation Procedure 1. Install the rear axle housing cover (2) and a new gasket. Notice: Refer to Fastener Notice. Important: Do not reuse the rear axle housing cover bolts. 2. Install the new rear axle housing cover bolts (1). Tighten the rear axle housing cover bolts in a crosswise pattern to 40 N.m (30 lb ft). 3. Fill the rear axle. Use the proper fluid. Refer to Approximate Fluid Capacities and Fluid and Lubricant Recommendations. 4. Lower the vehicle. Page 13368 Disclaimer Page 23095 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 12689 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 3906 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 10389 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 16135 Fuse: Application and ID Underhood Fuse Block Electrical Center Identification Views Fuse Block - Underhood, Label Page 268 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 8444 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 10825 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 9571 Page 12224 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 9949 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Notice: Refer to Fastener Notice. 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 N.m (92 lb in). 5. Install the control valve assembly. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 23072 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 23082 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 14792 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 18913 Page 1101 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 22486 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 20625 Disclaimer Technical Service Bulletin # 09-08-64-023 Date: 090603 Body - Outside Door Handle Pulls Out of Base TECHNICAL Bulletin No.: 09-08-64-023 Date: June 03, 2009 Subject: Outside Door Handle Pulls Out of Base, Loose Handle (Install Clip to Outside Door Handle Assembly) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Condition Customers may comment that the outside door handle is loose in the handle base. This condition is most common on the driver's door , however it can occur on any of the four outside door handles on the vehicle. This condition is more prevalent in warmer climates. Cause The pins that retain the handle to the base at its forward pivot point can be pulled out of the base (The handle does not fall off of the vehicle). This occurs in hot temperatures when the handle is pulled in an outboard and rearward motion when opening the door. Correction A new clip has been designed to prevent the legs of the fork area of the handle from collapsing and letting the handle pull out. Use the following procedure to install the clip into the outside door handle assembly. 1. Remove the outside door handle that is experiencing the concern. - Use the published procedure in SI for Front Side Door Outside Handle Replacement for front door handle service. - Use the published procedure in SI for Rear Side Door Outside Handle Replacement for rear door handle service. 2. With the back of the handle assembly exposed, reposition the handle to properly engage the pivot pins into the handle base. With the handle pivot pins properly engaged, install the service clip (1). 3. Reinstall the handle to the vehicle and verify its function. Parts Information Page 7875 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 483 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 7335 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 13155 Control Module: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Page 17858 Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500, 2500 LD) Page 22476 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 13022 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 8011 Crankshaft Position Sensor: Service and Repair Crankshaft Position System Variation Learn Crankshaft Position System Variation Learn 1. Install a scan tool. 2. Monitor the engine control module (ECM) for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Testing and Inspection/Diagnostic Trouble Code Descriptions 3. Select the crankshaft position (CKP) variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 1. Accelerate to wide open throttle (WOT). 2. Release throttle when fuel cut-off occurs. 3. Observe fuel cut-off for applicable engine. 4. Engine should not accelerate beyond calibrated RPM value. 5. Release throttle immediately if value is exceeded. 6. Block drive wheels. 7. Set parking brake. 8. DO NOT apply brake pedal. 9. Cycle ignition from OFF to ON. 10. Apply and hold brake pedal. 11. Start and idle engine. 12. Turn A/C OFF. 13. Vehicle must remain in Park or Neutral. 14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) sensor activity-If there is a CMP sensor condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the CKP system variation learn procedure with a scan tool. Important: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 6. Accelerate to WOT. 7. Release when the fuel cut-off occurs. 8. Test in progress 9. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the applicable DTC that set. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315 See: Testing and Inspection/Diagnostic Trouble Code Descriptions 10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. 11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * A CKP sensor replacement * An engine replacement * A ECM replacement * A harmonic balancer replacement * A crankshaft replacement * Any engine repairs which disturb the CKP sensor relationship Page 10852 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6628 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 13623 Page 2408 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 8441 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 4098 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 10130 1. Relieve the fuel system pressure, if required. Perform the following steps: Caution: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 (2). 5. Remove the hose on the CH-48027-2 (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Notice: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections Disconnect the CH-48027-1 (1) from the CH-48027-2 (2). 2. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 3. Disconnect the CH-48027-3 (4) from the fuel rail service port. 4. Install the fuel rail service port cap. 5. Install the engine cover, if required. 6. Tighten the fuel fill cap. Page 12012 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 2520 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 16077 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 886 Body Control Module (BCM) X5 Electrical - Various Electrical Malfunction/Systems Inop Trailer Warning Indicator: Customer Interest Electrical - Various Electrical Malfunction/Systems Inop TECHNICAL Bulletin No.: 09-08-43-001 Date: March 25, 2009 Subject: Wipers Do Not Park in Correct Location, Various Electrical Concerns: Door Locks/Windows Inoperative, Radio Stays on After Driver's Door Opened, Telltales Illuminated (Diagnose Wiper Wiring, Relocate Ground Wire) Models: 2007-2009 Cadillac Escalade Models 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the windshield wipers do not park in the correct location. In addition to this wiper concern, customers may also comment on any of the following conditions: - High/low headlamp beam selection switch, power door locks and/or power windows are inoperative. - Radio stays on after the driver's door has been opened. - Dome lamps remain on at all times. - Door Ajar message displays in the Driver Information Center (DIC). - Tow haul telltale lamp is either always illuminated or does not turn on. - Headlamps do not turn on or off when requested by the manual headlamp switch. Correction Note DO NOT replace the windshield wiper motor for this concern unless instructed to by the diagnostics. Wipers Do Not Park Circuit/System Testing 1. Access the wiper motor located under the cowl cover. Refer to Air Inlet Grille Panel Replacement procedure in SI. 2. With the ignition OFF, disconnect the harness connector at the windshield wiper motor (1). 3. Turn the ignition ON. Verify that the scan tool BCM Wiper Park Switch parameter is Inactive. - If not Inactive, test the signal circuit terminal 3 (1) for a short to ground. If the circuit tests normal, proceed to Wiring Repair below. If the circuit does not test normal, fix the short to ground. Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: All Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 9677 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Notice Silicon Contamination of Heated Oxygen Sensors Notice Notice: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Temperature Versus Resistance Page 14057 Valve Body: Diagrams 6L50/6L80/6L90 - Automatic Transmission Control (With Body and Valve) Valve Assembly Disassembled Views (6L80) Door Lock and Side Window Switch Replacement - Driver Side Power Door Lock Switch: Service and Repair Door Lock and Side Window Switch Replacement Driver Side Door Lock and Side Window Switch Replacement - Driver Side Diagrams Fuel Level Sensor: Diagrams Displays and Gages Connector End Views Fuel Pump and Sender Assembly - Front (Gas) Fuel Pump and Sender Assembly - Rear (Gas +LY6) Page 9894 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 16289 Junction Block - Rear Lamps Junction Block - Rear Lamps X1 Page 2113 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 23127 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 2323 Page 12202 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 21363 Disclaimer Communication Interface Module Replacement (without RPO SLT) Central Control Module: Service and Repair Communication Interface Module Replacement (without RPO SLT) Communication Interface Module Replacement (without RPO SLT) Page 22207 Page 16294 Fuse Block - Underhood X2 Page 20757 Remove the seal only in the affected area. Inspect the seal's channel crimp and adjust accordingly by pinching the channel together for a tighter retention. Reinstall the portion of the seal that was removed. Warranty Information For vehicles repaired under warranty, use the appropriate labor operation found in the Labor Time Guide (LTG). Disclaimer Page 21031 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Front Door Opening Weatherstrip Replacement (Crew Cab) Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement (Crew Cab) Front Door Opening Weatherstrip Replacement (Crew Cab) Removal Procedure 1. Remove the front door sill plate. Refer to Front Side Door Sill Plate Replacement (Regular Cab/Crew Cab) Front Side Door Sill Plate Replacement (Extended Cab) . 2. Remove the weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the weatherstrip to the door opening with the 2 dots positioned on the upper right and left side. 2. Align the weatherstrip to the door opening with the bond joint positioned at the lower center of the door opening. Page 3018 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Locations Timing Component Alignment Marks: Locations * Look to ensure that the crankshaft sprocket is aligned at the 12 o'clock position and camshaft sprocket is aligned at the 6 o'clock position. Page 20561 Page 20155 For vehicles repaired under warranty use, the table. Disclaimer Page 16009 Page 8618 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 20091 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 3193 1 - Outside Rearview Mirror - Passenger 2 - Door Lock Switch - Passenger (AU3 -AN3/DL3) 3 Passenger Door Switch (PDS) (AN3/DL3) 4 - Door Latch Assembly - Passenger 5 - Inflatable Restraint Side Impact Sensor (SIS) - Right Front (ASF) 6 - Speaker - Right Front 7 - Window Motor - Passenger (A31) 8 - Window Switch - Passenger (A31 -AN3/DL3) 9 - Heated Seat Switch Passenger (AN3) Left Rear Door (Extended Cab) Page 14428 For vehicles repaired under warranty, use the table. Disclaimer Page 5581 Tighten the bolts to 9 N.m (80 lb in). 2. Install the spark plug wires. Page 23573 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Park/Neutral Position Switch Replacement Tools Required J 41364-A Park Neutral Switch Aligner Removal Procedure 1. Apply the park brake. 2. Shift the transmission into neutral. 3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. 4. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 5. Disconnect the park/neutral position (PNP) switch electrical connector (2). 6. Remove the manual shaft lever nut. 7. Remove the transmission control lever from the manual shaft. 8. Remove the PNP switch bolts. 9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs. Installation Procedure Page 15936 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 8966 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14926 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Sunroof Track Timing/Synchronization (Extended Cab) Sunroof / Moonroof Track: Service and Repair Sunroof Track Timing/Synchronization (Extended Cab) Sunroof Track Timing/Synchronization (Extended Cab) Removal Procedure 1. Place the module in the full open position. 2. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (Regular Cab) Headlining Trim Panel Replacement (Extended Cab) Headlining Trim Panel Replacement (Crew Cab). 3. Disconnect the electrical connector from the motor/actuator. 4. Remove the motor/actuator. 5. Push the window guides rearward on the track until the guides are positioned against the rear hard stop. Installation Procedure 1. Install the motor/actuator. 2. Connect the electrical connector to the motor/actuator. 3. Install the headliner. 4. Perform the Initialization/Teach Procedure. Refer to Sunroof Motor/Actuator Initialization/Teach Process. See: Testing and Inspection/Programming and Relearning 5. Verify the operation of the sunroof. Page 12896 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 14107 Important Use ONLY a clean nylon brush that is DEDICATED to the repair of this specific condition. With a one-inch nylon bristle brush, apply dielectric lubricant P/N 12377900 (in Canada, 10953529 to both the module/component side and the harness side of the affected connector(s). 3. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 4. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Page 16252 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 2459 Vehicle Zoning Strategy Truck Zoning Page 16497 X800 - X899 Inline Harness Connector End Views X800 Body Harness to Right Rear Door Harness (Crew Cab) Page 2338 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 18004 Frequently Asked Questions Disclaimer Page 6053 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 19817 Page 10390 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 12262 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 22044 Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Weatherstrip Replacement (Extended Cab) Sunroof Window Weatherstrip Replacement (Extended Cab) Removal Procedure 1. Remove the sunroof window. 2. Carefully remove the sunroof window weatherstrip (2) from the perimeter of the sunroof window (1). Installation Procedure 1. Carefully install the sunroof window weatherstrip (2) to the perimeter of the sunroof window (1), ensuring that the weatherstrip is fully seated. 2. Install the sunroof window. 3. Ensure that the sunroof does not have any air or waterleaks. Page 2346 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 6792 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. A/C - Blower Motor is Inoperative Blower Motor: Customer Interest A/C - Blower Motor is Inoperative TECHNICAL Bulletin No.: 08-01-38-002 Date: April 10, 2008 Subject: Blower Motor Inoperative (Replace Blower Motor) Models: 2007-2008 Chevrolet Silverado Extended and Crew Cab Models Only 2007-2008 GMC Sierra Extended and Crew Cab Models Only with Electronic Temperature Control HVAC System (RPO C67) Built Prior to 4/01/08 Condition Some customers may comment that the blower motor is inoperative. Correction Technicians are to replace the blower motor. The new blower motor assembly P/N 25973845 contains a new moisture shield. Refer to Blower Motor Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 16947 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 5016 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 9762 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 12462 Disclaimer Page 22542 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Page 5140 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 13804 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 4861 2. Lubricate the O-ring seal with clean engine coolant. 3. Install the water outlet. Notice: Refer to Fastener Notice. 4. Install the water outlet bolts. Tighten the bolts to 21 N.m (15 lb ft). 5. Install the radiator inlet hose. 6. Install the air cleaner outlet resonator duct. Page 556 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 1805 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Symptoms - Data Communications Information Bus: Testing and Inspection Symptoms - Data Communications Symptoms - Data Communications Important: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle before using the symptom tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data links. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Data Link Communications Description and Operation. Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the systems. * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections. See: Testing and Inspection/Component Tests and General Diagnostics Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Scan Tool Does Not Power Up * Scan Tool Does Not Communicate with High Speed GMLAN Device * Scan Tool Does Not Communicate with Low Speed GMLAN Device Page 11801 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 7845 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 2209 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Front Disc Brake Pads Replacement (JD9, JF3, JF7) Brake Pad: Service and Repair Front Disc Brake Pads Replacement (JD9, JF3, JF7) Front Disc Brake Pads Replacement (JD9, JF3, JF7) Page 11164 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 19382 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Page 23590 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 13258 5. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible. 6. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts. 7. Remove the TCC solenoid bolts. 8. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body. 9. Reposition the harness to the side of the transmission case. 10. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body. 11. Remove the transmission fluid pressure switch. Page 7967 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 4L60-E/4L65-E/4L70-E - Automatic Transmission Vehicle Speed Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 22939 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 6930 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 22198 Page 14886 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Antilock Brake System Automated Bleed Procedure Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Procedure (W/JL4) Antilock Brake System Automated Bleed Procedure (With JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Using the scan tool, begin the automated bleed procedure. 4. Follow the instructions on the scan tool to complete the automated bleed procedure. Apply the brake pedal when instructed by the scan tool. 5. Turn the ignition OFF. 6. Remove the scan tool from the vehicle. 7. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). 9. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 10. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 11. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 12. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 13. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes 14. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 15. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. (W/O JL4) Antilock Brake System Automated Bleed Procedure (Without JL4) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Important: This procedure may be performed on all vehicles EXCEPT those equipped with option code JL4, Vehicle Stability Enhancement System (VSES). Important: The base hydraulic brake system must be bled before performing this automated bleeding procedure. If you have not yet performed the base hydraulic brake system bleeding procedure, refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure) before proceeding. 1. Install a scan tool to the vehicle. 2. Start the engine and allow the engine to idle. 3. Depress the brake pedal firmly and maintain steady pressure on the pedal. 4. Using the scan tool, begin the automated bleed procedure. 5. Follow the instructions on the scan tool to complete the automated bleed procedure. Release the brake pedal between each test sequence. 6. Turn the ignition OFF. 7. Remove the scan tool from the vehicle. 8. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or Page 4173 Frequently Asked Questions Disclaimer Page 4002 Fuse Block: Locations Entertainment/Communication Component Views Entertainment/Communication Component Views Behind the I/P 1 - I/P Trim 2 - Fuse Block - I/P 3 - Body Control Module (BCM) 4 - Speaker - Subwoofer (UQA) 5 Vehicle Communication Interface Module (VCIM) (UE1 +YE9) 6 - Digital Radio Receiver (U2K) Page 19392 Driver/Vehicle Information Display: Diagrams Object Detection Connector End Views Object Detection Connector End Views Information Center Telltale Assembly Page 6794 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 12826 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 15343 Front Brake Caliper Bracket Replacement (JD9, JF3, JF7) Front Brake Caliper Bracket Replacement (JD9, JF3, JF7) Page 3467 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 7246 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 9933 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 19325 Disclaimer Page 21561 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Sunroof Air Deflector Replacement (Crew Cab) Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement (Crew Cab) Sunroof Air Deflector Replacement (Crew Cab) Page 10421 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 21350 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Page 9476 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 6917 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 15594 Page 13023 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 21792 Page 24521 Service Procedure Important The windshield solvent heater module (1) is located on the driver's side of the engine compartment near the front fender upper brace (if equipped), master cylinder reservoir, and lower plenum panel. For the Cadillac DTS and Buick Lucerne, the windshield solvent heater module is mounted to the front of dash on the passenger's side of the engine compartment. 1. Locate the windshield solvent heater module. 2. Disconnect the windshield solvent heater module wire harness (1) from the heater module (2). 3. Connect the jumper harness with the in-line fuse (1) to the windshield solvent heater module wire harness (2) as shown in the illustration. Basecoat/Clearcoat Paint Systems Paint: Application and ID Basecoat/Clearcoat Paint Systems Basecoat/Clearcoat Paint Systems Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. All paint finish repairs of rigid exterior surfaces must meet GM standards. Refer to the latest revision of the GM Approved Refinish Materials book GM P/N GM4901M-D to identify the paint systems you may use that have been engineered to meet GM standards. The GM Approved Refinish Materials book supplies all approved products, including volatile organic compound (VOC) compliant regulations recommended by the individual manufacturer, and detailed procedures for materials used in their paint system. The booklet is now located on the Goodwrench website www.gmgoodwrench.com. Page 16402 Page 12840 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 15238 Page 2999 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 15547 Warranty Information This installation procedure is to be performed at the customer's request and at their expense. It is not a warranty repair and a claim should not be submitted for reimbursement. Disclaimer Page 21797 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 6104 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 23335 procedure. What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Recycle it by taking it to a place that collects used oil. Page 475 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 6632 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10679 10. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 11. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 12. If equipped with 2-wheel drive (2WD) perform the following steps, disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. Refer to Plastic Collar Quick Connect Fitting Service. 13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. 14. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 15. Remove the fuel line bracket bolt (2). 16. Remove the fuel/EVAP line clip nut (1). 17. Remove the fuel/EVAP line clips from the frame and crossmember. 18. Remove the fuel/EVAP line assembly from the vehicle. Page 24732 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 15260 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Page 15133 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (JF3/JF7) Electronic Brake Control Module (JF3/JF7) Page 7205 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 12550 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 2787 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 21631 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Caution: Refer to Brake Dust Caution. 1. Inspect the brake caliper housing for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seals for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seals and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. Insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Page 10822 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 21125 Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Front Side Door Emblem/Nameplate Replacement (Chevrolet Silverado) Front Side Door Emblem/Nameplate Replacement (Silverado Sierra 2500) Front Side Door Emblem/Nameplate Replacement (Silverado Sierra 2500) Page 22474 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Page 3147 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8478 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 7625 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 6323 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 10496 36. Open valve (3) at the bottom of J 38500-A. 37. Connect a shop air source to the fitting at the top of J 38500-A and adjust the regulator (1) to 75 psi. 38. Let the vehicle run at idle until the canister is empty and the vehicle stalls. 39. Remove the shop air supply from J 38500-A. 40. Depressurize the J 38500-A. 41. Disconnect the J 38500-A hose from the J 44466-12. 42. Remove the PCV clean air tube from the air inlet duct and set aside. 43. Remove the resonator and air inlet duct from the throttle body and set aside. 44. Remove ignition wires 1, 3, and 5 from the distributor cap. 45. Remove brake booster vacuum hose and connector from the intake manifold. 46. Bleed the residual pressure from J 44466-12. 47. Remove J 44466-13 (1) and J 44466-12 (2) from the metering body. 48. Remove J 44466-13, retainer, and J 44466-11 from the fuel feed pipe. Important: Make sure that all of the O-rings (6 and 8), washers (7), and spacers (5) are present and in proper position. 49. Install the fuel feed pipe (4) to the metering body. Notice: Refer to Fastener Notice. 50. Install the retainer (1) and retainer nuts (2). Page 1090 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 15490 3. Position the park brake pedal assembly on the side panel. Notice: Refer to Fastener Notice. 4. Install and finger tighten the mounting nuts. Tighten the nuts to 25 N.m (18 lb ft). 5. Connect the park brake warning lamp connection. 6. Install the park brake release handle to the instrument panel. 7. Install the park brake release handle bolt. Tighten the bolt to 9 N.m (80 lb in). 8. Install the hinge pillar trim panel. 9. Install the left side instrument panel electrical center/junction block. 10. Raise the vehicle. Page 17073 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 2020 Page 9971 Catalytic Converter: Service and Repair Catalytic Converter Replacement (4.3L) Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the oil pan skid plate bolts and skid plate, if equipped. 3. Remove the transmission crossmember. 4. Remove the right front connector position assurance (CPA) retainer. 5. Disconnect the right front heated oxygen sensor (HO2S) electrical connector (5) from the engine wiring harness electrical connector (4). 6. Remove the right rear CPA retainer. 7. Disconnect the engine wiring harness electrical connector (2) from the right rear HO2S electrical connector (1). 8. Remove the right rear HO2S electrical connector clip from the engine harness clip (3). Page 734 Page 11910 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 1990 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 9306 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 21776 Paint: Specifications Clearcoat Thickness The clearcoat on the vehicle is typically 0.059-0.078 mm (1.5-2 mils [0.0015-0.0020 in]) thick. The clearcoat contains ultraviolet screeners. Removing more than 0.5 mils (0.019 in) of the clearcoat may result in early paint failure. Page 12869 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 16476 X303 Body Harness to Driver Seat Harness (-AN3) Page 7569 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 7110 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 6683 Page 4384 Page 10620 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 19887 Disclaimer Page 2518 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 2591 * The vehicle is not in a reduced engine power mode. * The ignition is ON. * The engine is OFF. 7. Install the knee bolster. Page 711 Page 11483 Ignition Cable: Testing and Inspection Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation. A thorough inspection is necessary to accurately identify conditions that may affect engine operation. Inspect for the following conditions: 1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 2. Any signs of cracks or splits in the wires. 3. Inspect each boot for the following conditions: * Tearing * Piercing * Arcing * Corroded terminal If corrosion, or arcing are indicated on a spark plug wire boot a terminal, replace the wire and inspect the components connected to the wire. Page 22482 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2275 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 10179 Vehicle Zoning Strategy Truck Zoning Page 8392 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 22776 A removable insert, shown above, was added to the outer groove of the upper side rail clamp to help prevent improper positioning from unintentionally occurring. Check that the clamps are properly installed using the correct groove in the upper side rail clamp. Correct positioning is detailed in the illustration above. Cause #2 The condition may be caused by the tonneau bows not falling into proper position when the tonneau cover is rolled out. This cause would indicate that repositioning on an upper side rail clamp is needed. Correction #2 Note the position of the bows and use the appropriate repair below: - If bows do not fit between the side rails and additional clearance is required, remove the clamp nearest the interference. Remove the orange strip to allow access to the outer groove of the upper clamp. Reinstall the clamp, using the outer groove of the upper clamp. - If bows are too loose, adjust the clamp nearest the bow with excessive clearance to the inner groove of the upper clamp. Cause #3 This condition may be caused by a misalignment of the tonneau side rails and/or improper adjustment of the forward tension screws. The graphic above shows a misalignment of the tonneau side rail (1) to the front of the pickup box (2). Correction #3 1. Verify that the tonneau side rails are aligned with the front of the pickup box as shown above. 2. Ensure that the side rails are aligned with each other in the same fore/aft position (1) on the vehicle. Note Page 19349 Parking Assist Control Module: Service and Repair Object Alarm Module Replacement Page 12428 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 11132 Page 7084 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 9812 8. Connect the PNP switch electrical connector (2). 9. If equipped with 4WD, install the front propeller shaft. 10. Lower the vehicle. 11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch. Page 17050 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 11877 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 10803 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Crankshaft Position Sensor Replacement Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Crankshaft Position Sensor Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. If equipped, remove the oil pan skid plate and bolts. 3. Disconnect the engine wiring harness electrical connector (4) from the crankshaft position (CKP) sensor. Page 4413 Note: The vehicles shown must not be towed backwards or transmission damage may occur. Towing Procedure Note: Failure to follow these instructions may result in damage to the transmission. Important: The towing speed as stated in the Owner's Manual should not exceed 104 km/h (65 mph) for 1995-2005 vehicles. In order to properly dinghy tow the vehicle, follow these steps: 1. Firmly set the parking brake. 2. Open the fuse panel and pull the fuse(s) indicated in the Owner's Manual section detailing towing your vehicle. This prevents the instrument panel (IP) and/or electronic PRNDL indicator from draining the battery. 3. Securely attach the vehicle to the tow vehicle. 4. Turn the ignition key to the OFF position, which is one position forward of LOCK. Unlocking the steering column allows for proper movement of the front wheels and tires during towing. For 1997-1999 Cutlass, 1997-2003 Malibu, 2004-2006 Chevrolet Classic and 1999-2004 Alero/Grand Am models, turn the ignition switch to the accessory (ACC) position, which is one position forward of OFF. This position unlocks the transaxle. 5. Shift the transmission to Neutral (N). Note: Page 23146 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 14114 Procedures to Diagnose/Chafed Wiring Harness at Trans Case Information for the Procedures to Diagnose and Repair the Above Conditions 1. Perform the Diagnostic System Check-Vehicle to begin your diagnosis of these conditions. 2. Perform a thorough visual inspection of the vehicle. 3. Depending on the vehicle, some of the procedures may not be applicable. 4. The following procedure is the only one applicable to the Corvette and XLR. Chafed Wiring Harness at Transmission Case Retaining Clip and Inspection of the 16-way Electrical Connector for Backed Out Terminals 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Locate the 16-way electrical connector on the right side of the automatic transmission as shown. 5. Inspect for a pinched/cut wiring harness where it is attached at the transmission by a metal attachment clip as shown. Inspect any of these harness clips that you may observe as needed. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. Page 10797 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2155 2. Ensure that the fuel level sensor retainers (1) engage the module reservoir. 3. Install the fuel level sensor wiring pigtail under the module clip (2). 4. Connect the fuel level sensor wiring pigtail electrical connector (1) to the module cover. 5. Install the fuel tank module. Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 237 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 2193 Page 2043 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 3890 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 11553 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 11718 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12767 powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 12. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 11966 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 24308 1 - Window Switch - Right Rear (ABV) 2 - Window Motor - Right Rear (ABV) 3 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 4 - Speaker - Right Rear Door Page 3794 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 16988 The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Important: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation. GMLAN Connector Terminal Repair Important: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs for the appropriate connector repair procedure. See: Testing and Inspection/Component Tests and General Diagnostics GMLAN Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If a wire is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except coaxial. * Do not use the DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: Page 17112 2. Insert a small flat-blade tool in the slot below the front loaded terminal position assurance (TPA) and pry up. 3. Remove the TPA by pulling it out of the connector. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-553 (GM P/N 15315247) on a slight upward angle into the cavity below the terminal to be removed. Ensure that the pointed on the end of the tool is facing the bottom of the terminal and it stays in contact with the terminal until it stops on the plastic terminal retainer. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Gently pry the plastic terminal retainer down and carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Yazaki Connectors (16-Way) Yazaki Connectors (16-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Page 12724 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 8459 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 5261 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement (Non-HP2) Page 5091 Radiator Cooling Fan Motor: Service and Repair Engine Coolant Fan Motor Replacement (Non-HP2) Removal Procedure 1. Remove the cooling blade(s). 2. Remove the cooling fan motor bolts. 3. Remove the cooling fan motor(s). Installation Procedure 1. Install the cooling fan motor(s). Notice: Refer to Fastener Notice. 2. Install the cooling fan motor bolts. Tighten the bolts to 10 N.m (89 lb in). 3. Install the cooling fan blades. Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Tools Required j 41712 Oil Pressure Switch Socket Removal Procedure Important: Clean the area around the oil pressure sensor. Do not allow debris to enter the engine. 1. Disconnect the fuel pump/oil pressure sensor electrical connector (3). 2. Using J 41712, remove the fuel pump/oil pressure sensor. Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Step 1 - Step 7 Page 21383 Page 15327 perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes Pressure Hydraulic Brake System Bleeding (Pressure) Tools Required * J 29532 Diaphragm Pressure Bleeder, or equivalent * J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. Page 12572 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 12085 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 11029 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 11619 Knock Sensor: Description and Operation Knock Sensor (KS) System Description Purpose The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. Sensor Description This knock sensor (KS) system uses one or 2 flat response 2-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the control module through a low reference circuit. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. A normal KS signal will ride within the noise channel. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal, keeping the signal within the channel. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If knock is present, the signal will range outside of the noise channel. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will stay outside of the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose/damaged component or excessive engine mechanical noise. Page 16419 X228 Inline Harness Connector End Views X228 Beacon Harness to Chassis Harness (5Y0) X275 Inline Harness Connector End Views X275 Inflatable Restraint Steering Wheel Module Coil to Body Harness Page 5971 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 22578 Hood Sensor/Switch (For Alarm): Diagrams Immobilizer Connector End Views Hood Ajar Switch (AP3/AP8) Page 1617 Air Temperature Sensor - Lower Right Page 11729 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Locations Crankshaft Position Sensor: Locations Engine Controls Component Views Right Side of Engine 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 2778 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 12746 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 3126 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 1093 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 12231 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 10386 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 2026 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Instruments - Hard to See/Poor Backlighting Instrument Panel Control Module: All Technical Service Bulletins Instruments - Hard to See/Poor Backlighting Bulletin No.: 07-08-49-029A Date: January 25, 2008 TECHNICAL Subject: Instrument Panel (IP) Gauges/Gages Difficult to Read or See Poor Backlighting (Replace IP and Program) Models: 2007 Chevrolet Avalanche Silverado Suburban Tahoe 2007 GMC Sierra Sierra Denali Yukon Yukon Denali Yukon XL Yukon Denali XL Supercede: This bulletin is being revised to reflect the latest Utility software part number. Please discard Corporate Bulletin Number 07-08-49-029 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) gauges are difficult to read due to poor backlighting. This condition does not affect the IP cluster operation. Correction DO NOT program the service software into existing 2007 clusters. The service software is designed to work only with the 2008 cluster hardware, which includes a new microprocessor. For IP clusters replaced/programmed due to a customer concern of poor backlighting, warranty claims must be submitted using the labor operation listed in this bulletin. Refer to the Warranty Section for more information. Program the replacement IPC using TIS2WEB Pass-Thru Programming. Select "I/PC" from the Supported Controllers table in TIS2WEB to complete the programming. DO NOT select I/PC Set-up. Mileage and/or Engine Hours must be set by the ESC's prior to installing the IP in the vehicle. DENALI CUSTOMER'S ONLY - Please advise the customer that 2008 Denali clusters are not available. In order to correct this condition, a 2008 Yukon or Sierra cluster will have to be installed in the vehicle. The customer must advise the dealer whether they wish to keep the current 2007 Denali cluster or replace it with a 2008 Yukon or Sierra cluster (which will correct the condition). Programming a 2007 cluster with the 2008 service software can drain the battery and potentially cause a "no start" condition. If the customer is dissatisfied with the IP cluster visibility the current (2007) cluster should be replaced with the 2008 hardware/software. Refer to the charts listed in the Parts Information section of this bulletin to determine the new IP cluster and software part numbers. Page 8119 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 4210 Tire Pressure Sensor: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 18477 For vehicles repaired under warranty, use the table. Disclaimer Page 21550 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 18449 Discharge Air Temperature Sensor / Switch: Service and Repair Air Temperature Sensor Replacement - Lower Right Side Air Temperature Sensor Replacement - Lower Right Side Page 1922 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 6356 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Front Air Deflector Extension Replacement Air Dam: Service and Repair Front Air Deflector Extension Replacement Front Air Deflector Extension Replacement Page 1784 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 4703 20. Position the engine wiring harness and bracket. 21. Install the engine wiring harness bracket stud (1). Tighten the stud to 25 N.m (18 lb ft). 22. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve. Tighten the nut to 9 N.m (80 lb in). 23. Install the engine wiring harness ground nut and ground wire (1) to the rear of the right cylinder head. Tighten the nut to 16 N.m (12 lb ft). Locations Audible Warning Device Control Module: Locations Displays and Gages Component Views Chime Module (UL5) 1 - Chime Module (UL5) Page 9148 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 13413 1. Remove the yoke assembly from the transmission. 2. Obtain J 24171-A and install a 90 degree hook onto the end of the slide-hammer (1). 3. Position the 90 degree hook behind the rear face of the seal's outer case (2). 4. Remove the rear seal using the slide-hammer. 5. Inspect the seal bore for scratches. Remove any scratches in the seal bore using crocus cloth. Installation Procedure Important: Be sure the new seal has blue sealant coating the OD (4). This identifies the seal for use in the 1000 Series transmissions. The blue sealant identification is important because the 1000 Series transmissions have an overdrive ratio in fifth range and there is a potential for high output shaft speeds and resultant high seal temperature. 1. Align the seal so the seal lip (2) is outward and the face of the steel case (1) will be against the driving face (3) of the tool. Install the new seal onto J 43782. 2. Slide J 43782 over the output shaft until the seal enters the seal bore. Strike J 43782 with a mallet (1) to drive the seal into the seal bore. The seal is installed correctly when the shoulder of J 43782 squarely contacts the outer surface of the rear cover. 3. Install the yoke assembly onto the transmission. Torque Converter Fluid Seal Replacement Torque Converter Fluid Seal Replacement Tools Required * J 24171-A Seal and Dust Shield Remover * J 43772 Torque Converter Seal Installer Removal Procedure Page 9267 Page 6023 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Page 9017 Page 8605 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Engine - Drive Belt Misalignment Diagnostics Drive Belt: All Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 13222 1. Install the transmission oil cooler lines to the vehicle. 2. Install the cooling lines to the transmission. 3. Install the engine protection shield. 4. Lower the vehicle. 5. Install the transmission fluid cooler hose to the radiator. 6. Install the transmission fluid cooler hose to the auxiliary oil cooler. 7. Install the radiator grille. Page 9907 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 15817 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood, Label Brakes - Aftermarket Trailer Brake Controllers Trailer Connector: Technical Service Bulletins Brakes - Aftermarket Trailer Brake Controllers INFORMATION Bulletin No.: 06-08-45-008D Date: July 12, 2010 Subject: Information on Auxiliary Power Wire at Trailer and Installation of Aftermarket Trailer Brake Controller - Towing, Tow Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2011 HUMMER H2 Supercede: This bulletin is being revised to add the 2011 model year and information about the orientation of the ringlet. Please discard Corporate Bulletin Number 06-08-45-008C (Section 08 Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may have questions on how to connect an electric trailer brake controller or where the brake controller pigtail harness is located. Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. An aftermarket brake controller will need to be installed/connected to the blunt wires under the left side of the IP for vehicles built without JL1 - Integrated Brake Controller (full-size utilities and pickups). The following steps should be used to complete the installation. 1. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 2. Pull the trailering wire harness down. Page 1134 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 2858 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 14682 5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. 6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. 7. Install the transmission filter. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 8. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 2631 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Fastener Tightening Specifications Alignment: Specifications Fastener Tightening Specifications Fastener Tightening Specifications Fastener Tightening Specifications Page 3161 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 13 Vehicle Communication Interface Module (VCIM) X3 (UE1 +U3U/UVB) Page 20169 Method 3 The Gen 6.1 version of OnStar(R) does not require the use of the Service Programming System (SPS) to change the voice recognition system. However, there are three ways to change the language. Disclaimer Page 9958 Vehicle Speed Sensor (VSS) 1 - VSS Sensor 2 - Transfer Case Page 22408 Seat Heater: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 4693 37. Install the heater hose clamp (1). 38. Install the fuel pipes/hoses. 39. Install the ignition coil assembly. 40. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 23466 19. Reinstall the harness connectors (1) to the MSM. 20. Reinstall the seat to the vehicle. Heated and Cooled Seats (RPO KB6) Follow the steps below to correct the concern with the heated and cooled seats. 1. Inspect the ventilation heating and cooling module for a concern with the TED. Refer to Seat Heating and Cooling, Diagnostic Information and Procedures in SI. Note If the heated and cooled seat function is inoperative, but the heat switch indicators are On, the MSM is functioning properly and the concern is with the TED. 2. If the TED is found to be the concern, replace the seat cushion or seat back ventilation heating and cooling module. Refer to Driver or Passenger Seat Back Ventilation Heating and Cooling Blower Replacement or Driver or Passenger Seat Cushion Ventilation Heating and Cooling Blower Replacement in SI. If the TED is not the concern, follow normal diagnostics and repair in SI. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Warranty Information Use the appropriate Labor Operation based on the repair completed. Heated Seats (RPO AN3, KA1) For vehicles repaired under warranty, use: Heated and Cooled Seats (RPO KB6) Page 12232 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 10755 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 10796 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 4L60-E/4L65-E/4L70-E - Automatic Transmission Shift Solenoid: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Control and Shift Solenoids Replacement Removal Procedure 1. Remove the transmission filter. Important: Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid. 2. Remove the 1-2 accumulator, if necessary. 3. Disconnect the internal wiring harness electrical connectors from the following components: * Transmission fluid pressure switch (1) * 1-2 shift control solenoid (2) * 2-3 shift control solenoid (3) * Pressure control solenoid (4) * torque converter clutch pulse width modulation (TCC PWM) solenoid (5) * 3-2 control solenoid (6) 4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 5. Remove the pressure control solenoid (377). Page 3169 Page 3562 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: * Spark plug fouling-Colder plug * Pre-ignition causing spark plug and/or engine damage-Hotter plug 3. Inspect the terminal post (1) for damage. * Inspect for a bent or broken terminal post (1). * Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. 4. Inspect the insulator (2) for flashover, carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: * Inspect the spark plug boot for damage. * Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. 5. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Page 2782 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 12706 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 17699 5. Install the power steering pump fitting seal (3) to the power steering pump assembly (1). Notice: Refer to Fastener Notice. Important: Start the power steering fluid reservoir studs and the power steering pump flow control valve fitting by hand before finalizing any torques. 6. Install the power steering pump fitting (4) to the power steering pump assembly (1). Tighten the fitting to 75 N.m (55 lb ft). 7. Install the power steering fluid reservoir studs (2) to the power steering pump assembly (1). Tighten the studs to 58 N.m (44 lb ft). 8. Install the power steering pump assembly to the vehicle. Page 6679 Page 4904 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 8609 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 5364 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 10853 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 11134 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 10914 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 3896 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 9948 Transmission Position Switch/Sensor: Service and Repair Allison - Automatic Transmission Manual Shift Shaft, Detent Lever, and Position Switch Assembly Replacement Removal Procedure 1. Remove the control valve assembly from the transmission. Important: The detent lever/IMS retaining bolt contains patch lock material on the threads. Do not reuse the retaining bolt. 2. Remove the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit and discard the retaining bolt. Notice: DO NOT mar the transmission case surface around the spherical pin when removing or installing the spherical pin. An unmarred surface is required to maintain the seal between the control valve assembly and the transmission case. Notice: DO NOT twist the spherical pin when removing the pin from the transmission case. Damage to the transmission case can occur. 3. Place a protective plate on the transmission case surface around the spherical pin (3). Remove the spherical pin (3) from the transmission case. 4. Slide the manual shift shaft (5) through the detent lever/IMS assembly (4) and through the manual shift shaft seal. 5. Rotate the detent lever/IMS assembly to disengage the park pawl apply assembly (2). Remove the detent lever/IMS assembly (4). Installation Procedure Page 2238 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Restraints - Air Bag Lamp ON/Multiple DTC's Set Seat Belt Buckle Switch: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC's Set TECHNICAL Bulletin No.: 08-09-41-010 Date: October 29, 2008 Subject: Airbag Readiness Light On, DTC B0015, B0022, B0071, B0072 or B0073 Set (Perform Repair as Outlined) Models: 2007-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Sierra Denali, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL Condition Some customers may comment that the airbag readiness light is on. A scan tool may reveal one or more of the following DTCs set: B0015, B0022, B0071, B0072 or B0073. Cause One possible reason is the improper connection or high resistance at the front seat belt retractor and buckle connectors. Correction For DTCs B0015 and B0022 Before replacing the front seat belt retractor assembly, remove the components necessary to gain access to the connector (1) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and install CPA, GM P/N 12052834. 4. Clear the DTC and confirm the code does not reset. For DTCs B0071, B0072 and B0073 Page 7858 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 14163 6. For the 9.5/9.5LD inch and 11.5 inch axles, press the bearing off of the pinion using the J 22912-B. 7. Remove the shim. 8. Remove the outer pinion bearing cup from the axle housing using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the housing evenly. Page 2984 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 15885 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 6460 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 8095 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 12813 Backprobe Important: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Page 6312 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: Customer Interest A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 7166 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 16396 X123 X123 Engine Chassis Harness to Instrument Panel Harness (PTO) Page 6497 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 16720 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Diagrams Fuel Level Sensor: Diagrams Displays and Gages Connector End Views Fuel Pump and Sender Assembly - Front (Gas) Fuel Pump and Sender Assembly - Rear (Gas +LY6) Page 22500 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 5591 5. Install the insulator (1) to the intermediate muffler assembly hanger. 6. If equipped with a 5.3L, or a 6.0L engine, perform the following steps. 7. Lubricate the 3 insulators where the muffler assembly hangers are inserted in order to ease installation. 8. With the aid of an assistant, position and install the muffler assembly. 9. Install the insulators (1, 2) to the front and rear muffler assembly hangers. Page 13684 Important: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support. 17. Remove the range selector cable from the support. 18. Remove the cable grommet from the floor panel. 19. Remove the cable from the vehicle. Installation Procedure 1. Install the cable to the vehicle. 2. Install the cable grommet to the floor panel. Page 580 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 16238 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 16212 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 1739 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 15942 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 7065 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 22801 Before replacing the front seat buckle, remove the components necessary to gain access to the connectors (2, 3) and follow the procedure outlined below. 1. Inspect the connector for proper connection. Perform a tug test to determine if the connector was properly locked. 2. Disconnect the connector and inspect the terminals for signs of corrosion or other deposits. Repair as necessary and use dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins. 3. Reconnect the connector and CPA. 4. Clear the DTC and confirm the code does not reset. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8649 4. Connect the engine wiring harness electrical connector (2) to the HO2S pigtail electrical connector (1). 5. Install the CPA retainer. 6. Lower the vehicle. Page 1152 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 3398 Transmission Position Switch/Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft Position Switch Replacement Page 9912 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 10617 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 21937 For vehicles repaired under warranty, use the table. Disclaimer Page 11599 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 6705 Page 13935 Transmission Speed Sensor: Locations Power Take-Off Power Take-Off (PTO) Component Views Front Frame Rail 1 - X300 2 - G300 3 - Automatic Transmission Turbine Speed Sensor 4 - Automatic Transmission Input Shaft Speed (AT ISS) Sensor 5 - Automatic Transmission 6 - Vehicle Speed Sensor (VSS) 7 - X124 8 - Power Take Off (PTO) Module 9 - X175 Page 6575 Page 17751 21. Remove the connector from the sensor. 22. Remove the sensor from the adapter and bearing assembly. 23. To install the sensor, proceed to step 17 in the installation procedure. 24. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff (4) for installation * A foam ring (1) 25. Remove the connector from the sensor. 26. Remove the sensor from the adapter and bearing assembly. 27. To install the sensor, proceed to step 21 in the installation procedure. Installation Procedure Important: If reusing the existing sensor, no centering of the sensor is required. 1. If installing a new sensor, it will come with a pin installed in the sensor. Do not remove the pin until the sensor is seated. 2. From the technicians point of view, the FRONT of the sensor (1) connector will be on your right. From the technicians point of view, the BACK of the sensor (2) connector will be on your left. 3. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install into the adapter and bearing assembly. 4. Install the connector to the sensor. 5. From the technicians point of view, the FRONT of the sensor will have: Page 11397 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 11777 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 15497 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice. 2. Install the park brake warning lamp switch bolt. Tighten the bolt to 3 N.m (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. 5. Connect the negative battery cable. Page 19358 5. Verify that DTC B1E3A does not reset as Current. Important Ensure each leg of the circuit is tested since the 8 volt reference circuit feeds all the sensors in parallel. ‹› If DTC B1E3A does set, test the 8 volt reference circuit for a short to voltage, short to ground or an open/high resistance. Repair the circuit as necessary. Depending on the model year of the vehicle, refer to Body > Wiring Systems > Diagnostic Information and Procedures > Wiring Repairs OR Power and Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. ‹› If DTC B1E3A does not set proceed to Step 6. 6. Install each object sensor harness connector one at a time, checking for DTCs immediately after each sensor is connected. Verify DTC B1E3A does not set as Current. ‹› If DTC B1E3A does set, replace the object sensor that was connected immediately before the DTC set. 7. Perform the diagnostic repair verification after completing the diagnostic procedure. Refer to Diagnostic Repair Verification in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3027 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 6349 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 7357 View of the connector when released from the component. View of another type of Micro 64 connector. Page 22317 Page 16547 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 12626 Shift Solenoid: Electrical Diagrams 4L60-E/4L65-E/4L70-E - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams 6L50/6L80/6L90 - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Allison - Automatic Transmission For information regarding diagrams for this component, please refer to Transmission Control Systems diagrams. See: Transmission Control Systems/Diagrams/Electrical Diagrams Page 10939 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 2439 7. Remove the HO2S pigtail electrical connector clip (9) from the fuel line bracket. 8. Remove the HO2S (1). Installation Procedure Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (1). Entertainment System - Rear DVD Screen Inoperative/Blank DVD Player: All Technical Service Bulletins Entertainment System - Rear DVD Screen Inoperative/Blank TECHNICAL Bulletin No.: 06-08-44-032B Date: April 10, 2008 Subject: Rear (2nd and *3rd Row (*where applicable)) DVD Screen Blank/Inoperative, Speaker Pop Noise, Battery Draw, OnStar(R) Audio Inoperative, Nav Screen Flashing, Radio Display Flashing (Inspect and Repair Wiring Harness if Necessary) Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT* 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe* 2007-2008 Chevrolet Equinox 2007 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL* 2007-2008 Pontiac Torrent with Rear Seat Entertainment System (RPOs U42, UUC) Supercede: This bulletin is being revised to add RPO UUC. Please discard Corporate Bulletin Number 06-08-44-032A (Section 08 - Body and Accessories). Condition Some customers may comment on any one of the following concerns: ^ Rear DVD Screen Inoperative. ^ Pop Noise in all speakers when cranking the engine. ^ Battery Draw or Battery goes dead. ^ OnStar(R) Inoperative. ^ No Sound from speakers. ^ No OnStar(R) Audio. ^ Navigation screen "Flashing on and off". ^ Radio display "Flashing on and off". Cause This condition may be due to an open or shorted wiring harness near the rear DVD display screen under the headliner. Correction To properly inspect for this condition perform the following steps: 1. Lower the rear DVD screen. 2. Remove the four retaining screws that hold the DVD to the headliner. In order to remove the screen assembly from the overhead bezel a firm tug should be applied to unseat the Z-axis clip. Page 13750 Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Front Propeller Shaft Replacement Drive/Propeller Shaft: Service and Repair Front Propeller Shaft Replacement Front Propeller Shaft Replacement Tools Required J 43218 Clamp Pliers - Narrow Jaw Removal Procedure Important: Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the following components: * The propeller shafts * The wheel drive shafts * The pinion flanges * The output shafts Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly. 1. Raise the vehicle. Refer to Vehicle Lifting. 2. Remove the clamp (4) at the transfer case by prying up the exposed end of the clamp with a flat-bladed tool. 3. Reference mark the relationship of the propeller shaft to the front axle pinon yoke. Page 10618 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 10573 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Body - Front Door Window Regulator Squeak Noise Front Door Window Regulator: Customer Interest Body - Front Door Window Regulator Squeak Noise TECHNICAL Bulletin No.: 07-08-64-019C Date: April 08, 2011 Subject: Front Door Window Regulator Squeak Noise When Operated (Apply Lubricant) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add the 2011 and 2012 model years. Please discard Corporate Bulletin Number 07-08-64-019B (Section 08 - Body and Accessories). Condition Some customers may comment on a front door glass squeak when operated up or down. Cause There may be insufficient lubrication on the regulator rails. Correction Lubricate BOTH front door regulators at time of repair using the following procedure. 1. Remove the regulator following SI procedures. 2. Brush a small amount of lubricant on the entire length of both regulator rails. Refer to the illustration for lubricant location. 3. Cycle the door glass to verify that the noise is gone. 4. Reinstall the regulator following SI procedures. Parts Information Page 16718 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 7154 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 6326 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 2622 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. A/C - HVAC Control Module Lockup During Reprogramming Control Module HVAC: All Technical Service Bulletins A/C - HVAC Control Module Lockup During Reprogramming Bulletin No.: 06-01-39-014 Date: December 06, 2006 INFORMATION Subject: Information On HVAC Control Module Lockup During Reprogramming Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models with Automatic Temperature Control HVAC System (RPO CJ2) The purpose of this bulletin is to alert technicians to a condition they may encounter while trying to reprogram a Heating, Ventilation and Air Conditioning (HVAC) control module. If the HVAC control module reprogramming event is interrupted, the control module may go into a "lock up" mode. This will cause the HVAC control module to disable communications and a second try at reprogramming will fail. The interruption may be caused by a software anomaly inside the HVAC control module. If the HVAC reprogramming event was interrupted and a subsequent reprogramming attempt fails, perform a battery reset. This can be accomplished by either removing and reinstalling the HVAC BATT fuse, located in the underhood fuse block, or by disconnecting and reconnecting the HVAC control module connector C2. Connector C2 is grey in color with 16 cavities. Once the battery reset has been performed, the HVAC control module will resume communications and will then be able to be reprogrammed. The Warranty Parts Center (WPC) has received HVAC control modules that have been returned and described as non-functional but were tested with no problems found. If the module has been replaced due to a failed second attempt at reprogramming caused by the lock up, the module will be returned and charged back to the dealer. Technicians must also remember that after a new HVAC control module has been installed into a vehicle, it must be programmed, otherwise it will not be functional. Disclaimer Page 10904 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 11795 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Page 2383 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 19925 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Page 11159 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 427 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 14795 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 8069 Page 9734 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 6516 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: Customer Interest Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 3718 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Power Steering Gear Outlet Pipe/Hose Replacement (Gas With Hydroboost) Removal Procedure 1. Place drain pans under the vehicle as needed. Notice: Refer to Power Steering Hose Disconnected Notice. 2. Disconnect the power steering fluid cooler hose clamp and hose (3) from the steering gear (2). 3. Remove the power steering gear outlet pipe (1) from the steering gear (2). Installation Procedure Campaign - HVAC Blower Not Functional Runs Continuously Control Module HVAC: All Technical Service Bulletins Campaign - HVAC Blower Not Functional Runs Continuously SPECIAL COVERAGE Bulletin No.: 11046 Date: April 07, 2011 Subject: 11046 - Special Coverage Adjustment - Heating, Ventilation, and Air Conditioning Blower Not Fully Functional on All Blower Speeds, Inoperative, or Runs Continuously with the Ignition Off Models: 2003-2006 Chevrolet Avalanche, Suburban, Tahoe 2003-2007 Chevrolet Silverado 2003-2006 GMC Yukon, Yukon XL 2003-2007 GMC Sierra Equipped with Manual HVAC (CJ3) or Heavy Duty Heater (C42) Due to part availability, owner letters will be released in phases starting with older model year first. Owners for model year vehicles not included in first phase owner mailing will receive an owner advisory letter. The letter will inform the customer that parts are not yet available and that another letter will be sent to them when parts become available. A copy of this letter will be attached to the dealer message announcing this bulletin. In the meantime, if a customer brings their vehicle to the dealership with the condition described in this bulletin, repair the vehicle using the parts called out in this bulletin. Condition On some 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual heating, ventilation, and air conditioning (HVAC) system (CJ3) or heavy duty heater (C42), the interface between the electrical terminals of the relay resistor module and the wiring connector that powers the module may be incapable of conducting higher current levels for sustained periods of blower motor operation. In addition, moisture and other contaminants may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals. Either of the above may cause the relay resistor module or wiring connector to overheat, resulting in one or more of the following symptoms: - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position In very rare events, if the above symptoms are ignored, a fire could occur. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 240,000 km, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Dealers are to install a new blower motor resistor and resistor module connector. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after April 8, 2011 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to April 8, 2011 must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2003-2006 model year Chevrolet Avalanche, Suburban, Tahoe; GMC Yukon, Yukon XL; and 2003-2007 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a manual HVAC (CJ3) or heavy duty heater (C42). Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Applicable Warranties section in the Global Warranty Management system. Parts Information Page 14667 5. Remove the TCC PWM solenoid retainer. 6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts. 7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378). 8. Remove the pressure control solenoid (377). 9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness. Page 10726 Page 7476 * The areas surrounding the connections Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap. Page 22871 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Rear Side Door Bottom Auxiliary Sealing Strip Replacement (Extended Cab) Page 9725 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 6532 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 24722 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Tyco/Amp Connectors (CM 42-Way) Tyco/AMP Connectors (CM 42-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. Locate the connector position assurance (CPA) on the connector body and pull the CPA out. The CPA is on the wire harness side of connector. 2. Disconnect the connector from the component. Locations Ambient Light Sensor: Locations Lighting Systems Component Views Front of the I/P -YE9 Front of the I/P -YE9 1 - Driver Information Center (DIC) Switch (UK3) 2 - Instrument Panel Cluster (IPC) 3 - Radio 4 Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 - HVAC Control Module 6 - Inflatable Restraint I/P Module Disable Switch (C99) 7 - Power Take-Off (PTO) Switch 8 - Auxiliary Power Outlet - Front 2 9 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 10 Auxiliary Power Outlet - Front 1 11 - Transfer Case Shift Control Switch (NQF/NQH) 12 - Trailer Brake Control Panel Switch (JL1) 13 - Headlamp and Panel Dimmer Switch Page 7193 Page 5885 and the fuse for the ignition 1 voltage circuit is open, test the ignition 1 voltage circuit to the ECM for a short to ground. If the circuit tests normal, replace the ECM. 6. Connect a test lamp between the relay coil B+ and the relay coil control circuit. 7. Ignition ON, command the powertrain relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. ‹› If the test lamp is always ON, test the relay coil control circuit for a short to ground. If the circuit tests normal, replace the ECM. ‹› If the test lamp is always OFF, test the relay coil control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 8. Connect a 20A fused jumper wire between the relay switch B+ and the relay ignition 1 voltage circuit. 9. Ignition ON, engine OFF, monitor the EC Ignition Relay Feedback parameter with a scan tool. The parameter should display B+. ‹› If the parameter does not display B+, test the ignition 1 voltage circuit for an open/high resistance. If the circuit tests normal, replace the ECM. 10. If all circuits test normal, test or replace the relay. Component Testing 1. Ignition OFF, disconnect the powertrain relay. 2. Test for 65-110 ohms of resistance between terminals 85 and 86 of the relay. ‹› If the resistance is not within the specified range, replace the relay. 3. Test for infinite resistance between following terminals: * Terminal 30 and 86 * Terminal 30 and 87 * Terminal 30 and 85 * Terminal 85 and 87 ‹› If not the specified value, replace the relay. 4. Install a 20A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 1 ohm of resistance between terminals 30 and 87. ‹› If greater than the specified range, replace the relay. Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Relay Replacement (Within an Electrical Center) Relay Replacement (Attached to Wire Harness) * Underhood Electrical Center or Junction Block Replacement * Refer to Programming and Relearning for setup and programming. See: Testing and Inspection/Programming and Relearning Page 9355 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Instruments - Bulb Outage Detection Restoration Lamp Out Indicator: All Technical Service Bulletins Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection Notice: Refer to Engine Mounting Notice. 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Inspect for loose or missing bolts at the following locations: * Engine mount bracket to engine * Engine mount frame bracket to frame * Engine mount to engine mount bracket * Engine mount to engine mount frame bracket 3. Replace missing or loose bolts. Notice: Refer to Engine Lifting Notice. 4. In order to access the square tab on the right side of the engine remove the starter. Refer to Starter Motor Replacement (4.3L) Starter Motor Replacement (4.8L, 5.3L, 6.0L, and 6.2L) Starter Motor Replacement (6.6L). 5. Using a jack on the square tab at the rear of the engine block (left side shown) raise the engine in order to complete the following tasks: * Remove weight from the engine mount. * Place a slight tension on the rubber cushion. * Observe the engine mount while raising the engine. 6. Replace the engine mount if the following conditions exist: * Heat check cracks cover the hard rubber surface. * The rubber cushion is separated from the metal plate of the engine mount. * There is a split through the rubber cushion. 7. Install the starter, if removed. Page 6770 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 10305 * The areas surrounding the connections Important: If relieving the fuel pressure for the fuel pressure gage installation and removal, it is NOT necessary to proceed with the following steps. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4). 12. Disconnect the CH-48027-3 (4) from the fuel rail service port. 13. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 14. Install the fuel rail service port cap. 15. Install the engine cover, if required. 16. Tighten the fuel fill cap. Page 23240 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Page 1427 Seat Recline Position Sensor - Driver (AN3) Page 3463 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 21126 Endgate Emblem/Nameplate Replacement (Cheyenne LT LS) Endgate Emblem/Nameplate Replacement (Cheyenne LT LS) Page 3151 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 6886 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 275 Audio System - Static/Ignition Noise on AM Band Ground Strap: All Technical Service Bulletins Audio System - Static/Ignition Noise on AM Band TECHNICAL Bulletin No.: 08-08-44-016 Date: May 12, 2008 Subject: Ignition Noise On Radio AM Band (Install Spark Plug Wire Set And Ground Strap) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra with 4.3L Engine (VIN X - RPO LU3) Condition Some customers may comment on static or an ignition/electrical noise on the radio's AM stations. The ignition noise will be related to engine speed. The noise will not be present when the radio is on and the engine is not running. Cause This condition may be caused by energy from the # 1 spark plug wire, being in close proximity to the steering column input shaft, which couples energy onto the (electrically floating) steering system. Correction Technicians are to replace the spark plug wires on cylinders 1, 3 and 5 and install a ground strap on the power steering gear using the following procedure: 1. Replace the spark plug wire set on cylinders number 1, 3 and 5 with P/N 89060518. This set of spark plug wires will allow you to route the # 1 plug wire away from the steering input shaft. Ensure that all spark plug boots are properly seated at the spark plug and at the ignition coil. Refer to the Spark Plug Wire Replacement procedure in SI for more information. 2. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to the Lifting and Jacking the Vehicle procedure in SI. 3. Attach the smaller ring terminal end of the ground strap, P/N 06286800, to the power steering rack with a small hose clamp, P/N 11609970 (or equivalent part obtained locally). Refer to the illustration above, which shows the ground strap attached to the power steering rack. 4. Attach the larger ring terminal end to the frame using one of the splash shield mounting bolts. Remove the bolt from the splash shield and slide the ring terminal between the splash shield and the frame and then reinsert the splash shield bolt. 5. Lower the vehicle. 6. Verify proper operation of the radio. Parts Information Warranty Information Page 2261 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Locations Brake Fluid Level Sensor/Switch: Locations Antilock Brake System Component Views Left Side of the Engine Compartment 1 - Windshield Wiper Motor 2 - Power Brake Booster (JL4) 3 - Windshield Washer Solvent Heater (XA7) 4 - Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (- MYC) 7 - Brake Booster Vacuum Sensor (JL4)/Brake Master Cylinder Pressure Sensor (JL1) 8 - Brake Fluid Level Switch Page 5479 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 7161 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 23105 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 21623 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 24201 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 2389 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 23053 Page 10791 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 3821 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Manual Hydraulic Brake System Bleeding (Manual) Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, Page 12347 Tighten the bolt to 11 N.m (97 lb in). 16. Install the TCC solenoid with a NEW O-ring seal to the valve body. 17. Install the TCC solenoid bolts. Tighten the bolts to 11 N.m (97 lb in). 18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. 19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3). Page 586 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 10482 Fuel Injector 2 Fuel Injector 3 Page 3875 Junction Block - Left I/P, Label Electrical Center Identification Views Junction Block - Left I/P, Label Page 24552 use of any similar HWFS products that may be sold by aftermarket suppliers. Even though you have declined to have this safety recall performed on your vehicle, please be advised that if you change your mind, your GM dealer will always be available to remove the HWFS from your vehicle and provide reimbursement according to the terms described in the recall notification letter. As part of this declination process, your dealer will ask you to document your refusal to have Safety Recall 10153 performed on your vehicle by signing a Repair Order stating "customer declined recall repair". You will be given a copy of this document for your records. Of course, your signature is voluntary but doing so will help prevent the mailing of recall reminder notices to you as the current owner of record. If you sell this vehicle, you should advise the buyer that this safety recall was not performed on the vehicle and that the recall repair is still available. This notice should also be placed in the glove box so that a future owner of this vehicle will be aware of this safety recall. Page 24014 Front of the I/P +YE9 Front of the I/P +YE9 1 - Instrument Panel Cluster (IPC) 2 - Inflatable Restraint Steering Wheel Module 3 - Shift Control Lever 4 - Ambient Light/Sunload Sensor Assembly (CJ2)/Ambient Light Sensor (C67/C42) 5 Speaker - Center (UQA +Y91) 6 - Radio 7 - Inflatable Restraint I/P Module 8 - I/P Compartment Lamp 9 - HVAC Control Module 10 - Auxiliary Power Outlet - Front 2 11 - I/P Multifunction Switch Assembly (JL4/JF4/UD7/XA7) 12 - Auxiliary Power Outlet - Front 1 13 - Driver Information Center (DIC) Switch (UK3) 14 - Steering Wheel Control Switch Assembly - Right (UK3) 15 - Steering Wheel Control Switch Assembly - Left (K34/KA9) 16 - Trailer Brake Control Panel Switch (JL1) 17 Headlamp and Panel Dimmer Switch 18 - Dimmer Control Page 6464 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 7466 Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Loosen the air cleaner outlet resonator clamp (1) at the mass air flow (MAF)/intake air temperature (IAT) sensor. 2. Remove the air cleaner outlet resonator from the MAF/IAT sensor. 3. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. Page 22970 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. Page 1370 Driver Door Switch (DDS) X1 (AN3/DL3) Driver Door Switch (DDS) X2 (AN3/DL3) Page 8226 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Extended Cab w/26 Gal Tank) Fuel Tank Pressure Sensor Replacement (Extended Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 22682 Important Ensure that the foam is securely wedged between the outboard edges of the insulator and the wiring harnesses/sheet metal, making sure that any C-pillar wiring harnesses/connectors are routed forward of the insulator and foam, and not trapped behind either of them. 5. Install a length of *Duck Brand Window Air Conditioner Insulating Strip Seal P/N 1284075, or equivalent, down each side C-pillar. 6. Complete the installation of the insulator panel and interior trim. Refer to Body Rear Panel Insulator Replacement (Extended Cab/Crew Cab) in SI. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Contact Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Duck Brand products, or equivalent, can be obtained from your local hardware or home improvement store. *GM‹›P/N‹›12378195 is not available in Canada. However several equivalents such as Evercoat (Q-Pads) P/N 100116 and Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 are available through NAPA Auto Parts retailers. Information for finding your local retail location can be obtained online at www.napacanada.com. Dominion Sure Seal (Sound Deadener Pads) BSDE Part 110900 can be obtained by contacting Dominion Sure Seal at 1-800-265-0790. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 11518 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 9594 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Lighting - Turn Signals Have Increased Flash Rate Body Control Module: All Technical Service Bulletins Lighting - Turn Signals Have Increased Flash Rate Bulletin No.: 07-08-42-003 Date: February 06, 2007 TECHNICAL Subject: Turn Signals Have Increased Flash Rate (Reprogram BCM) Models: 2007 Chevrolet Silverado 1/2 Ton Crew Cab Only 2007 GMC Sierra 1/2 Ton Crew Cab Only Built at Oshawa (VIN 1) Prior to VIN Breakpoint 71529814 Condition Some customers may comment that the turn signals are flashing faster than normal for no apparent reason. This condition may affect the right, left or both turn signals. Cause This condition may be due to a variation in components and software in the BCM. Correction A revised calibration has been developed to address this issue. Reprogram the BCM using SPY with the latest software available on TIS2WEB. As always, make sure your Tech 2(R) is updated with the latest software version. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7150 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 14116 1. Locate the terminal position assurance (TPA) as shown. Note The TPA cannot be removed from the connector while there are terminals present in the connector body. 2. Use a small flat blade tool to push the TPA until it bottoms out. 3. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Use the J-38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Note If the female terminal(s) must be replaced, it is part number 22124472200. It is located in Yazaki tray number 12 in the J-38125 Terminal Repair Kit. Page 9137 Page 6302 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 14243 Axle Bearing: Service and Repair Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) Rear Axle Shaft Seal and/or Bearing Replacement (w/Rear Drum) Tools Required * J 8092 Universal Driver Handle-3/4 in - 10 * J 21128 Axle Pinion Oil Seal Installer * J 23690 Axle Shaft Bearing Installer * J 2619-01 Slide Hammer * J 44685 Rear Axle Seal and Bearing Remover Removal Procedure 1. Remove the axle shaft. 2. Remove the axle shaft seal and the bearing from the axle housing using the J 44685 (1) and the J 2619-01 (2). Installation Procedure 1. Install the axle shaft bearing using the J 23690 (1) and the J 8092 (2). 2. Drive the axle shaft bearing into the axle housing until the tool bottoms against the tube. Page 7324 Knock Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 4150 Fuse Block - Underhood X2 (Pin A1 To M5) Page 8526 Page 15828 8. Remove the engine wiring harness lead nut (2). 9. Remove the engine wiring harness lead (5) from the starter. 10. Remove the starter from the vehicle. Important: If the starter shield is damaged, replace the starter shield. Page 6433 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor/Intake Air Temperature Sensor Replacement Removal Procedure Important: Use care when handling the mass air flow (MAF)/intake air temperature (IAT) sensor. Do not dent, puncture, or otherwise damage the honeycell located at the air inlet end of the MAF/IAT. Do not touch the sensing elements or allow anything including cleaning solvents and lubricants to come in contact with them. Use a small amount of a non-silicone based lubricant, on the air duct only, to aid in installation. 1. Remove the air cleaner outlet resonator. 2. Disconnect the engine wiring harness electrical connector (1) from the MAF/IAT sensor. 3. Loosen the MAF/IAT sensor seal clamp (1). 4. Remove the MAF/IAT sensor from the air cleaner assembly. Page 5869 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 11176 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 21105 Hood Weatherstrip: Service and Repair Hood Rear Seal Replacement Hood Rear Seal Replacement Page 23959 Marker Lamp - Right Rear (Z88) Roof Marker Lamp - Left (U01) Diagram Information and Instructions Courtesy Lamp: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 10258 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 3334 3. Install the 1-2 accumulator cover and pin assembly (57). 4. Install the 1-2 accumulator cover bolts (58, 59). Tighten the bolts to 10 N.m (89 lb in). Ball Check Valves 5. Install the 7 checkballs into the valve body. 6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. Page 5399 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 12138 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7623 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8510 Manifold Pressure/Vacuum Sensor: Diagrams Engine Controls Connector End Views Manifold Absolute Pressure (MAP) Sensor Page 494 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 10413 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Locations Air Flow Meter/Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 9188 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 3397 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Notice: Refer to Fastener Notice. 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 N.m (92 lb in). 5. Install the control valve assembly. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 8155 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Accessories - Aftermarket Trailer Brake Controller Trailer Brake Control Module: All Technical Service Bulletins Accessories - Aftermarket Trailer Brake Controller INFORMATION Bulletin No.: 07-08-45-001F Date: November 09, 2010 Subject: Procedure for Installation of an Aftermarket Trailer Brake Controller Models: 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2011 GMC Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 HUMMER H2 with Integrated Trailer Brake Controller Supercede: This bulletin is being revised to combine information from bulletins 06-08-45-008D and 07-08-45-001E. Please discard Corporate Bulletin Numbers 07-08-45-001E and 06-08-45-008D (Section 08 - Body and Accessories). Important Installation of an electric brake controller and the wiring connections outlined in this bulletin are the responsibility of the dealership or customer. These repairs should never be charged to warranty. If you have any questions, please consult with your District Service Manager. Some customers may request to have an aftermarket trailer brake controller added to their vehicle, OR in lieu of the factory integrated trailer brake controller (ITBC) (RPO JL1). Installation Instructions Starting with the new 2007 full-size utilities and pickups and 2008 HUMMER H2, there is no longer an electric trailer brake controller pigtail harness. To install an aftermarket trailer brake controller, use the four blunt cut wires located near the data link connector. The following steps should be used to complete the installation. Important Ensure that the ringlets are not interfering with the UBEC cover. 1. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. 2. ONLY For Vehicles Equipped with JL1 - Locate connector X126 or X115 (varies with vehicle build; refer to SI) near the underhood fuse block. Refer to SI Document ID# 1849049 - I/P Harness-Engine Compartment. Circuit 47 from the blunt cut wires near the data link connector will end Page 599 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 2497 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 23841 Page 11858 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 9673 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 Page 6911 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Filler Tube Replacement (Regular Cab w/26 Gal Tank) Fuel Filler Hose: Service and Repair Filler Tube Replacement (Regular Cab w/26 Gal Tank) Filler Tube Replacement (Regular Cab w/26 Gal Tank) Removal Procedure 1. Remove the fuel tank filler housing to body TORX(R) screws (1) and pushpin retainer (2). 2. Remove the fuel tank filler housing to fuel tank fill pipe bolts. 3. Remove the fuel tank filler housing. 4. Raise and suitably support the vehicle half way. Refer to Vehicle Lifting. 5. Remove the fuel tank fill pipe ground wire bolt (3). 6. Remove the fuel tank fill pipe ground wire (2) anti-rotation tab from the frame hole. 7. Reposition the fuel tank fill pipe ground wire and chassis harness ground wire (1). Page 11854 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Locations Power Seat Motor Position Sensor: Locations Power Seat Component Views Driver Seat 1 - Seat Recline Motor - Driver (AN3) 2 - Seat Lumbar Vertical Motor Position Sensor - Driver (AN3) 3 - Seat Lumbar Vertical Motor - Driver (AN3) 4 - X324 (AN3) 5 - Seat Lumbar Horizontal Motor - Driver (AN3) 6 - Seat Lumbar Horizontal Motor Position Sensor - Driver (AN3) 7 - Seat Recline Position Sensor - Driver (AN3) 8 - Seat Lumbar Switch - Driver (AN3) 9 - Seat Adjuster Switch - Driver (AG1) 10 - Memory Seat Module (AN3) Locations Starter Motor: Locations Right Side of Engine (4.3L) 1 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 2 - Throttle Body 3 - Mass Air Flow (MAF) / Intake Air Temperature (IAT) Sensor 4 - X112 5 - G103 6 - Crankshaft Position (CKP) Sensor 7 - Knock Sensor (KS) - 2 8 - Starter 9 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 10 - Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 11 - Vehicle Speed Sensor (VSS) Right Side of the Engine (Gas -4.3L) Page 19818 Page 6060 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 9295 * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. Page 16760 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 14609 Transmission Position Switch/Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 24310 Window Switch - Left Rear (Crew Cab +A31/Extended Cab +ABV) Locations Accelerator Pedal Position Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) 1 - Electronic Adjustable Pedal Assembly (JF4) 2 - Stop Lamp Switch 3 - Accelerator Pedal Position (APP) Sensor Page 16938 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 17191 For vehicles repaired under warranty, use the table. Disclaimer Page 15943 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 7135 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 11396 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 14916 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 7138 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 17592 D Height Measurement Important: The left and right D height difference should be no more than 14 mm (0.55 in). Use the following procedure to measure the D height. 1. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3 times. 4. Measure between the axle bracket and jounce bumper mount bracket as shown in graphic. 5. Lift the rear bumper of the vehicle up about 38 mm (1.5 in). 6. Gently remove your hands and let the vehicle settle. 7. Repeat this operation 2 more times for a total of 3 times. 8. Re-measure the D height as in step 4. 9. The true D height is the average of the measurement from step 4 and step 8. The side to side difference in D height must not exceed 14 mm (0.55 in). 10. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Page 11515 Page 17349 X126 Inline Harness Connector End Views X126 Instrument Panel Harness to Chassis Harness (-JL4) Page 6514 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 22616 For vehicles repaired under warranty, use the table. Disclaimer Page 12940 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 14899 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 15383 Brake Hose/Line: Service and Repair Front Brake Hose Replacement (JD9, JF3, JF7) Front Brake Hose Replacement (JD9, JF3, JF7) Page 20231 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Stop Lamp Switch Brake Light Switch: Diagrams Stop Lamp Switch Lighting Systems Connector End Views Stop Lamp Switch Page 12886 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 17627 Steering Angle Sensor: Removal and Replacement Steering Wheel Position Sensor Replacement Page 8608 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 1303 Hood Sensor/Switch (For Alarm): Diagrams Immobilizer Connector End Views Hood Ajar Switch (AP3/AP8) Page 10066 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Page 12672 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Instruments - Bulb Outage Detection Restoration Body Control Module: Customer Interest Instruments - Bulb Outage Detection Restoration INFORMATION Bulletin No.: 07-08-42-006E Date: November 11, 2010 Subject: Information on BCM Calibrations Available to Restore Bulb Outage Detection on Vehicles Produced by a Second Stage Manufacturer, Turn Signals Flash Fast after Factory Box Removed (Upfitter) Models: 2007-2011 Chevrolet Silverado 2007-2011 GMC Sierra Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 07-08-42-006D (Section 08 - Body and Accessories). The information contained in this bulletin applies to vehicles that are to be completed by a second stage manufacturer (upfitter) and may need to have the Body Control Module (BCM) rear turn signal bulb outage detection capability changed. All production vehicles will be manufactured with one of the following BCM rear turn signal bulb outage detection software options: 1. A standard production vehicle will have BCM software that checks for two bulbs functioning in each rear turn signal bulb circuit. If one or more bulbs are inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 2. Certain 2500 and 3500 models can be ordered with a new option (RPO 9U5) where the BCM checks for one bulb functioning in each rear turn signal bulb circuit. If the bulb goes inoperative, the BCM will "fast flash" the Instrument Panel Cluster (IPC) turn signal indicator as required by Federal Motor Vehicle Safety Standard (FMVSS) 108 and Canada Motor Vehicle Safety Standard (CMVSS) 108. 3. A vehicle built with a pickup box delete or chassis cab option (RPO ZW9) will be produced with a BCM program that has no turn signal bulb outage detection capability (LED compatible). The IPC turn signal indicator will flash at the same rate no matter how many turn signal bulbs are inoperative. In some cases, the upfitter may wish to change the turn signal bulb outage detection capability so that the turn signals work correctly with their upfit or to meet certain requirements. This will require contacting the Techline Customer Support Center (TCSC) to open a case and obtain a Vehicle Configuration Index (VCI) number. Advise the TCSC consultant which turn signal bulb outage detection capability is needed: 1. Factory standard production TWO bulb outage detection. 2. Optional (RPO 9U5) ONE bulb outage detection. NOTE: ONLY AVAILABLE ON CERTAIN 2007-2011 MODEL 2500 AND 3500 VEHICLES. 3. NO bulb outage detection (LED compatible). The BCM can then be reprogrammed with the correct software. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5178 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 21053 Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement (Crew Cab, Power) Rear Side Door Window Regulator Replacement (Crew Cab, Power) Page 17595 4. Set the top edge of the level on the reference surface of the steering knuckle (C) and extend the level directly under the rear end of the front attachment bolt of the lower control arm (A). 5. While keeping the level in contact with the knuckle reference surface, adjust the level up/down until the bubble indicates it is horizontally level. 6. Extend a tape measure straight down from the center of the attachment bolt. The point where the tape measure and the level intersect is your first measurement. 7. Keep the top edge of the level on the reference surface of the steering knuckle (C) and move the level directly under the front end of the rear attachment bolt of the lower control arm (B). 8. Extend a tape measure straight down from the center of he attachment bolt. The point where the tape measure and the level intersect is your second measurement. 9. Push the front bumper of the vehicle down about 38 mm (1.5 in) 10. Gently remove your hands and let the vehicle settle. 11. Repeat this operation 2 more times for a total of 3 times. 12. Re-measure the Z height. 13. The true Z height is the average of the measurements taken. Refer to Trim Height Specifications. If any of these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Z Height Adjustment 1. For vehicles equipped with a torsion bar suspension, turn the bolt (1) that contacts the torsion arm as needed. One revolution of the bolt (1) into the nut increases the Z height by approximately 6 mm (0.2 in). 2. For vehicles without torsion bars, replace damaged or worn components as necessary. 3. If these measurements are still out of specifications after adjustment or are not equipped with torsion bars, inspect for the following: * Sagging front suspension-Refer to Torsion Bar and Support Assembly Replacement (Bushing Style). * Collision damage Page 13197 Fluid - A/T: Service and Repair Allison - Automatic Transmission Automatic Transmission Fluid and Filter Replacement Removal Procedure Important: DO NOT drain the fluid if only the transmission external oil filter is being replaced. 1. Remove the drain plug (6) and drain plug seal (5). Drain the transmission fluid into a suitable container. 2. Inspect the drained fluid. Important: Use a standard strap-type filter wrench to remove the transmission external oil filter. 3. Remove the filter (4) by rotating in the counterclockwise direction. 4. Remove the magnet (2) from the filter adapter (1) in the converter housing or from the top of the transmission external oil filter (3). 5. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required. Installation Procedure 1. Install the magnet (2) onto the filter adapter (1) which is in the converter housing. 2. Lubricate the gasket (3) on the transmission external oil filter with transmission fluid. 3. Install, by hand, the transmission external oil filter (4) until the gasket on the filter touches the converter housing. Notice: Turning the transmission external oil filter more than ONE FULL TURN after gasket contact will damage the filter and may cause fluid leakage. 4. Turn the filter ONE FULL TURN ONLY after gasket contact. Notice: Refer to Fastener Notice. 5. Install the drain plug (6) and drain plug seal (5). Tighten the drain plug to 35 N.m (26 lb ft). 6. Refill Transmission with DEXRON(R)VI Automatic Transmission Fluid. Refer to Fluid Capacity Specifications. Important: DTC P0701 may often set following fluid service. Cycling the ignition clears the code and allows Drive or Reverse range to be attained. Page 1577 Yaw Rate Sensor: Diagrams Yaw Rate and Lateral Acceleration Sensor (JL4) Yaw Rate and Lateral Acceleration Sensor (JL4) Page 11983 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 21951 Sunroof / Moonroof Module: Diagrams Sunroof Connector End Views Sunroof Module Page 4407 8. Install the tire and wheel. 9. Remove the safety stands. 10. Lower the vehicle. Page 24159 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 23154 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 3944 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 5146 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Page 15192 perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes. See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes Pressure Hydraulic Brake System Bleeding (Pressure) Tools Required * J 29532 Diaphragm Pressure Bleeder, or equivalent * J 35589-A Brake Pressure Bleeder Adapter Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J 29532, or equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175-205 kPa (25-30 psi). 9. Open the J 29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement Removal Procedure Important: Mark, sort, and organize all the components for assembly. 1. Remove the rocker arm cover. 2. Remove the rocker arms. 3. Remove the rocker arm supports. 4. Remove the pushrods. 5. Clean and inspect the rocker arms and/or pushrods, if necessary. Refer to Valve Rocker Arm and Push Rod Cleaning and Inspection. Installation Procedure Important: Be sure to keep parts in order. Parts must be reinstalled into the original location and position. Page 4629 Tighten the bolts to 12 N.m (106 lb in). 3. Install the oil cooler hose bracket bolt (1). Tighten the bolt to 25 N.m (18 lb ft). 3. For 2500 series vehicles, raise the differential carrier into position. 4. Install the differential carrier left side upper bolt and nut until snug. 5. Install the differential carrier left side lower bolt and nut until snug. 6. Install the differential carrier right side nuts. Tighten the bolt to 100 N.m (74 lb ft). 7. For 1500 series vehicles, raise the differential carrier into position. 8. Install the differential carrier right side nuts. 9. Install the differential carrier left side bolts. Locations Shift Interlock Solenoid: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 6297 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 21582 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Restraints - Airbag Light On DTC B0071 And B0081 Set Seat Belt Buckle: All Technical Service Bulletins Restraints - Airbag Light On DTC B0071 And B0081 Set TECHNICAL Bulletin No.: 07-09-41-010D Date: May 03, 2010 Subject: Airbag Light On, DTC B0071 and B0081 Set (Diagnose and Replace Right Front Seatbelt Buckle, If Necessary) Models: 2006-2010 Buick Lucerne 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Chevrolet Monte Carlo 2006-2008 Chevrolet Impala 2007-2010 Chevrolet Avalanche, Colorado, Silverado LD, Suburban, Tahoe 2007-2010 GMC Canyon, Sierra LD, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2006-2010 HUMMER H3 2009-2010 HUMMER H3T Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 07-09-41-010C (Section 09 - Restraints). Condition Some customers may comment on the airbag light being illuminated. Upon investigation, the technician may find DTC B0071 set in the passenger presence system (PPS) and a DTC B0081 in the sensing and diagnostics module (SDM). Correction Verify proper system electrical connections. Inspect the passenger seat belt tension sensor signal, voltage reference and low reference circuits, carefully for cutting and/or chaffing per SI instructions for DTC B0071. If all checks have been made and no fault has been found, replace the belt tension sensor. Important The seat belt tension sensor is not serviced separately. The seat belt buckle with the tension sensor must be serviced as a complete unit. Parts Information For part number and usage of seatbelt buckles, refer to Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 15406 Page 6697 Important: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the old sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 1. If reinstalling the old HO2S, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. Notice: Refer to Fastener Notice. 2. Install the HO2S (2). Tighten the sensor to 42 N.m (31 lb ft). 3. Connect the HO2S pigtail electrical connector (5) to the engine wiring harness electrical connector (4). 4. Install the CPA retainer. 5. Lower the vehicle. Locations Turn Signal Relay: Locations Electrical Center Identification Views Fuse Block - Underhood, Label Page 14708 Vehicle Zoning Strategy Truck Zoning Page 12567 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 11652 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 6622 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 2910 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 9258 Page 9742 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 13260 17. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 18. Remove the 7 valve body checkballs. Important: Some models do not have an outer spring. Note spring usage during removal. 19. Remove the accumulator cover bolts (58, 59). 20. Remove the 1-2 accumulator cover and pin assembly (57). Seat Belts Repairs and Inspections Required After a Collision: Service and Repair Seat Belts Repairs and Inspections Required After a Collision Caution: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: * Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. * Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. * Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. * Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Drivetrain - Whine Type Noise From Vehicle rear Drive/Propeller Shaft: All Technical Service Bulletins Drivetrain - Whine Type Noise From Vehicle rear Bulletin No.: 07-04-17-002 Date: October 25, 2007 TECHNICAL Subject: Whine Type Noise Coming from Rear of Vehicle (Diagnose and Replace Rear Propeller Shaft) Models: 2007-2008 Chevrolet Silverado Crew Cab, Ext Cab Standard (Regular) Box (1500 Series) (2WD Only) 2007-2008 Chevrolet Tahoe (2WD Only) with 4L60-E Automatic Transmission (RPO M30) (EXCEPT Police Package (RPO PPV)) 2007-2008 GMC Sierra Crew Cab, Ext Cab Standard (Regular) Box (1500 Series) (2WD Only) 2007-2008 GMC Yukon (2WD Only) with 4L60-E Automatic Transmission (RPO M30) Condition Some customers may comment on a slight whine noise coming from the rear of the vehicle at certain speeds, typically between 72-96 km/h (45-60 mph). Cause Rear axle "Inherent" ring and pinion gear whine. All gear driven units, such as automotive rear axles, produce some level of noise that cannot be eliminated with conventional adjustments and repairs. "Inherent" axle noise can be described as a slight noise heard only at a certain speed (typically between 72-96 km/h (45-60 mph) on most General Motors(R) trucks). The presence of this noise is not indicative of a functional concern with the axle assembly. However, some customers may find that this "inherent" axle noise is unacceptable. Correction Replace the rear propeller shaft with an aluminum service shaft (utilities) or with a tuned torsional damper shaft (pickups) ONLY after a road test and diagnosis concludes that it is an "inherent" rear axle noise and no physical damage or incorrect adjustment exists. If the noise is not correctly diagnosed as "inherent" and having a peak in the narrow speed range of 72-96 km/h (45-60 mph), the addition of a tuned torsional damper propeller shaft can aggravate the perceptible noise level. It is extremely important to first diagnose the rear axle noise as "inherent" before installing a new tuned torsional damper propeller shaft. Diagnostic Information and Procedures Available in SI for Rear Axle Noise Diagnostic Starting Point - Rear Drive Axle Symptoms - Rear Drive Axle Rear Drive Axle Noises Noisy in Drive Noisy When Coasting The Cadillac Escalade already has a released propeller shaft damper for production. It has a different u-joint size than the 2WD Chevrolet Tahoe and GMC Yukon, so the service propeller shaft in this bulletin would not work on these vehicles. The Escalade has a swaged steel tube shaft with a damper on the end. Drivetrain - Rear Drive Axle Whine Noise Universal Joint: All Technical Service Bulletins Drivetrain - Rear Drive Axle Whine Noise Bulletin No.: 06-04-17-002A Date: January 12, 2007 TECHNICAL Subject: Rear Drive Axle Whine Noise (Replace Slip Yoke Assembly) Models: 2004-2007 Chevrolet Silverado (Classic) 1500 Series 2WD Crew Cab Models (C15543) 2004-2007 GMC Sierra (Classic) 1500 Series 2WD Crew Cab Models (C15543) Supercede: This bulletin is being revised to include additional model information. Please discard Corporate Bulletin Number 06-04-17-002 (Section 04 - Driveline/Axle). Condition Some customers may comment on a slight axle whine noise heard only at certain speeds, typically on coast conditions between 72-96 km/h (45-60 mph). Cause "Inherent" ring and pinion gear whine. All gear driven units, such as automotive rear axles, produce some level of noise that cannot be eliminated with conventional adjustments and repairs. "Inherent" axle noise can be described as a slight noise heard only at a certain speed (typically between 72-96 km/h (45-60 mph) on most General Motors(R) trucks). The presence of this noise is not indicative of a functional concern with the axle assembly. However, some customers may find that this inherent axle noise is unacceptable. Correction Using the service procedures in SI, replace the propshaft front slip yoke and u-joint with a tuned damper slip yoke with u-joint assembly, P/N 19151749, ONLY after diagnosis concludes that it is an "inherent" rear axle noise and no physical damage or incorrect adjustment exists. Do NOT replace the propshaft assembly. If the noise is not correctly diagnosed as "inherent" and having a peak in the narrow speed range of 72-96 km/h (45-60 mph), the addition of a tuned damper slip yoke and u-joint can aggravate the perceptible noise level. It is extremely important to first diagnose the rear axle noise as "inherent". Refer to the following diagnostic information and procedure for rear axle noise in SI: Diagnostic Starting Point - Rear Drive Axle Symptoms - Rear Drive Axle Rear Drive Axle Noises Noisy in Drive Parts Information Warranty Information Page 23168 Navigation Software Update Procedure: Use the following procedure to update the Navigation Radio software using the Nav Software Update Disc P/N 25956121 (software version 0B92): This software update can only be used to update the navigation radios specified in this bulletin. DO NOT use this software to update any other vehicle's navigation radio. The Map DVD will be needed to verify the system operation after the software update has been performed. Use the vehicle's existing map DVD. It is recommended to wear latex gloves while performing the software update, to avoid fingerprints on the product and discs. DO NOT stop the engine until all tasks are completed. The software update MUST be performed with the engine RUNNING and the gear position in PARK. If the vehicle is turned off prior to the software update being completed, the process may not work again and a new Navigation Radio may be required. The software update requires using the map DVD slot. The update will not work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Start the engine, with the gear shifter in PARK - wait until the audio or caution screen is displayed after the opening screen. Press the "NAV" hard key. Press "OK" soft key. Press the "MENU" hard key. Press the "NAV" soft key. Press the "MAP DATABASE INFORMATION" soft key. Press the "CHANGE" soft key. The navigation radio automatically ejects the map DVD. Remove the ejected disc. Load the update disc into the slot located behind the display screen by inserting it partially until the system pulls it in. DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. The screen "PREPARING TO LOAD SYSTEM SOFTWARE" will be displayed while the update is loading. The update should take approximately 4 Page 274 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 1947 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 2429 Oxygen Sensor: Connector Views Engine Controls Connector End Views Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 Page 4027 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 8195 Fuel Level Sensor: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 23902 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 22440 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 14124 4. Inspect the wiring harness along the left side frame rail at the body mounts for chafed/shorted wiring as shown. 5. If the wiring is damaged, repair as needed. Refer to Wiring Systems and Power Management > Diagnostic Information and Procedures > Wiring Repairs in SI. 6. Protect the harness by covering the sharp edge with butyl tape or a suitable material. Secure the harness as needed. 7. Lower the vehicle. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Clear any DTCs that may be present with a scan tool and verify the proper operation of the vehicle. Chafed Wiring Harness Near Data Link Resistor Chafed Wiring Harness Near Data Link Resistor Causing Intermittent No/Crank and/or Scan Tool Does Not Communicate with High Speed GMLAN Device 1. Turn OFF the ignition and all accessories. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 4. Typical location of a data link resistor (3) mounted on the chassis. Page 22428 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2262 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 22679 4. If a void is found (1), fill it with seam sealer Kent Automotive High-Tech(TM) Clear Sealer, P/N P10200 (5 oz. tube), or equivalent, to eliminate the air flow escape concern. 5. Before reinstalling the trim, inspect the insulator mat that is mounted on the body rear inner panel to ensure the access flap is fully seated/closed as shown above. 6. Reinstall the trim panels and rear seat. Refer to Body Lock Pillar Trim Replacement (Crew Cab) or Body Lock Pillar Trim Replacement (Extended Cab) in SI. Correction #2 Note This repair is ONLY for 2010 models that have the original body rear panel insulator (pictured above) and exhibit a higher noise penetration into the cab, when compared to a similarly equipped 2009, or earlier, model. Note that the insulator shape is flat across the bottom edge. Tip Before any repairs, you can visually verify which insulator the vehicle has by looking under the rear seat on the right or left side. If you can see the body Page 5904 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 19461 Page 21176 Page 7008 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 14449 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 22746 Towing Hook / Bracket: Service and Repair Tow Hook Replacement (2500HD/3500 Series) Tow Hook Replacement (2500HD/3500 Series) Page 16749 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. Page 8231 Information Bus: Locations Data Communication Component Views Behind the I/P 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) (Export) Below the Driver Knee Bolster Page 23016 Page 9418 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Tank Pressure Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank. 2. Remove the fuel tank pressure sensor by pulling straight up using a slight rocking motion. Installation Procedure 1. Install the fuel tank pressure sensor. 2. Install the fuel tank. Page 658 Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Service Procedure Note The resistor module connector and blower motor resistor will need to be replaced if one or more of the symptoms below is present. - The HVAC blower may not function on certain or all blower speed settings - A burning plastic smell or smoke may be present in the vehicle - The HVAC blower may run continually with the ignition in the OFF position Determine if one or more of the above symptoms is present. If required refer to HVAC diagnostic information in SI. Refer to Resistor Module Connector and Blower Motor Resistor Replacement in this bulletin if one or more of the symptoms is present. Other HVAC repairs are NOT covered in this product safety special coverage bulletin. Resistor Module Connector and Blower Motor Resistor Replacement 1. Remove the blower fuses (Htr A/C & HVAC 1 fuses). 2. Lower the close-out panel enough to gain access to the resistor module connector. 3. Disconnect the connector from the resistor module. Note Connector replacement is required even if the connector was replaced on a previous service repair. 4. Remove the tape from the wiring harness to expose the wiring. 5. Cut the wires back far enough from the connector to eliminate any melted insulation on the wire. Note Use the old connector as a map for splicing the wires for the new connector. Be sure to use the correct crimping tool from the terminal repair kit J 38125. Use only Duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. 6. Install the new connector. Use the yellow splice sleeves provided with the connector. 7. Install the new blower motor resistor. 8. Reinstall the fuses. Test the blower motor to make sure all speeds are functional. 9. Reinstall the hush panel/close-out panel. Customer Reimbursement Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by December 31, 2012. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 240,000 kilometres, whichever occurs first. When a customer requests reimbursement, they must provide the following: Page 11431 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 21613 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 12184 Page 9039 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Rear Object Sensor Housing Replacement Parking Assist Distance Sensor: Service and Repair Rear Object Sensor Housing Replacement Rear Object Sensor Housing Replacement 1. Remove the center rear bumper step pad or the rear bumper impact bar end cap. 2. Disconnect the sensor harness. 3. Remove the sensor from the sensor housing. The sensor housing must be painted if replaced. If reinstalled, painting will not be necessary. Important: Do Not grind off alignment tabs. 4. Sand/grind sonic weld plastic residue from the fascia. Page 23238 Fuel Gauge Sender: Service and Repair Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Special Tools J 45722 Fuel Sender Lock Ring Wrench Removal Procedure 1. Remove the fuel tank. 2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. 3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. 4. Reposition the fuel and EVAP pipes out of the way. 5. Install the J 45722 (1) to the fuel tank module lock ring. Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Important: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation. Page 10099 Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine/Chassis (Extended Cab) Evaporative Emission Hoses/Pipes Replacement - Engine/Chassis (Extended Cab) Removal Procedure Important: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. 3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. Page 2623 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 507 - Find the wire on the schematic and convert the metric size to the equivalent American wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 11918 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 11012 Page 4295 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 4695 4. Remove the engine wiring harness clips (1, 2) from the engine harness brackets. 5. Remove the engine wiring harness rear bracket bolts and bracket. Page 17390 Inline Harness Connector End Views X501 Left Front Door Harness to Body Harness (YE9 -AN3/DL3) X502 Inline Harness Connector End Views Page 8038 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 11285 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 6175 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 14822 3. For a new TCC PCS (7), install O-rings and lubricate with clean transmission fluid. Push the new TCC PCS (7) into the control valve assembly with the wiring harness connector in the correct position. 4. Install the TCC PCS retainer and bolt. Tighten the bolt to 12 N.m (108 lb in). 5. For a new SS 1 (5), install O-rings (3 and 4) and lubricate with clean transmission fluid. Push the new SS 1 (5) into the control valve assembly with the wiring harness connector in the correct position. Install the solenoid retainer (2). 6. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 7. Perform the FastLearn procedure. Page 9290 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 6983 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 13913 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: * The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. * Apply the park brake. * The engine must start in the park (P) or neutral (N) positions only. * Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 8315 4. Locate the dress cover locking tabs at the rear of the connector. Use a small flat-blade tool to release the locking tabs. Repeat this procedure for the other locking tab. 5. Once the locking tabs are unlocked, slide the inner connector out of the rear of the connector housing. Page 14569 12. Inspect the transmission fluid pressure manual valve position switch assembly for the following conditions: * Damage * Debris * Damaged or missing O-rings * Cracked connector * Loose electrical terminals * Poor terminal retention 13. Remove the manual detent spring bolt. 14. Remove the manual detent spring. 15. Inspect the manual detent spring for cracks or damage. Important: Keep the valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages. 16. Remove the remaining valve body bolts. Page 14844 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 11181 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 8278 View of the connector when released from the component. View of another type of Micro 64 connector. Page 6173 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 15786 Notice: Refer to Fastener Notice. 2. Install the generator bracket bolts and nut. Tighten the bolts/nut to 41 N.m (30 lb ft). 3. Install the drive belt idler pulley. 4. Install the drive belt tensioner. 5. Install the generator. Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 Body Control Module: All Technical Service Bulletins Electrical - Low Battery Voltage/Warning Lamp/ DTC B1516 TECHNICAL Bulletin No.: 06-06-03-013D Date: September 30, 2009 Subject: Intermittent Low Battery Voltage, Engine Will Not Crank, Engine Cranks But Will Not Start, Charging System Light On, Service Battery Charging System Message Displayed, Headlamp Flicker or Dimming, DTC B1516 Set (Reprogram BCM) Models: 2007 Cadillac Escalade Models 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon Models 1500 and 2500 Series Vehicles Only Assembly Plants Breakpoint for Changed Calibration from February 5, 2007 through February 9, 2007 Supercede: This bulletin is being revised to add additional symptoms. Please discard Corporate Bulletin Number 06-06-03-013C (Section 06 - Engine/Propulsion System). Condition Some customers may comment of one or more of the following conditions: - Charging system light on. - Service battery charging system message displayed. - Intermittent low battery voltage. - Vehicle will not crank. - Vehicle cranks but will not start. - Diagnostic Trouble Code (DTC) B1516 - Battery Current Sensor Performance Signal Invalid. - Headlamp flicker or dimming. Cause This condition may be caused by the Body Control Module (BCM) calibrations that create a lower battery state of charge than intended in low electrical power usage modes. Correction Important Verify that the 12-volt battery has a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics 165-PCS charger or equivalent to maintain proper battery voltage during programming. The J2534 MDI will reprogram the modules in less time than the Tech 2(R) scan tool. A revised calibration has been developed to address these conditions. Technicians are to reprogram the BCM using the latest software available on TIS2WEB. Refer to the Body Control Module Programming and Setup procedure in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 19956 Built After and Including the VIN Breakpoints shown. The Generation (Gen) 6.1 OnStar(R) system found in these vehicles has the capability to change the default English voice recognition to French or Spanish. Changing the language of the OnStar(R) system will change the following features to the language you select: Voice recognition command prompts will be played in the language selected. The voice recognition system will only recognize commands given in the selected language. Once completed, this process completely changes all voice recognition and voice commands of the OnStar(R) system. The process will need to be repeated in its entirety to change to a different language, including English. Page 6319 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 23570 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 56 Disclaimer Page 1075 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 3097 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 23395 damaged or warped. * Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring. * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Capacity Specifications Fluid - Differential: Capacity Specifications AXLE CAPACITIES FRONT AXLE 1000 Series (8.25") ...................................................................................................... ..................................................................... 1.43 liters (1.51 quarts) 2000 Series (9.25") .................. ......................................................................................................................................................... 1.73 liters (1.83 quarts) REAR AXLE 1000 Series With RPO AXN (9.5" LD) ........................................................................... ...................................................................................... 2.6 liters (2.75 quarts) Without RPO AXN (8.6") .................................................................................................................................................... ............. 2.03 liters (2.15 quarts) 2000 Series (9.5" HD) ..................................................................... ................................................................................................... 2.6 liters (2.75 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 23098 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. The connector nose piece acts as a terminal positive assurance (TPA) and may be referred to as such. 3. Use a small flat-blade tool to push in one of the locking tabs while gently pulling on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. Page 16005 Fuse: Locations Left I/P Junction Block Junction Block - Left I/P, Label Junction Block - Left I/P, Device Usage Page 1834 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9439 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Page 8211 Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Tools Required J 45722 Fuel Sender Lock Ring Wrench Removal Procedure Page 13418 Seals and Gaskets: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Manual Shift Shaft and Seal Replacement Manual Shift Shaft and Seal Replacement Page 12574 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure 1. While depressing the lock, remove the connector from the component. Page 5482 Page 8902 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 11616 Page 17853 Cross-Member: Service and Repair Transmission Support Crossmember Replacement (2WD 1500/2500) Transmission Support Crossmember Replacement (2WD 1500/2500) Page 13356 Control Module: Service and Repair 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Control Module Replacement Page 24672 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Air Bag System - DTC B0071/B0074/B0081 Code Clearing Seat Occupant Sensor: All Technical Service Bulletins Air Bag System - DTC B0071/B0074/B0081 Code Clearing Bulletin No.: 07-09-41-004 Date: June 13, 2007 INFORMATION Subject: New Procedure for Clearing Passenger Presence System (PPS) and Sensing and Diagnostic Module (SDM) DTCs B0071, B0074, B0081 Models: 2006-2008 Buick Lucerne 2006-2008 Cadillac DTS 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2006-2007 Monte Carlo 2006-2008 Chevrolet Impala 2007-2008 Chevrolet Silverado, Suburban, Tahoe 2007-2008 GMC Yukon, Yukon Denali, Yukon XL, Yukon XL Denali A condition exists where the passenger presence system (PPS) may continue to output a fault to the sensing and diagnostic module (SDM) after the PPS has been cleared. The fault may continue to report to the SDM if the buss has not been allowed to go to sleep prior to clearing B0081 DTC in the SDM. If B0071, B0074 or B0081/0F is received, the following procedure should be followed to clear the codes. With the Ignition OFF, open and close the driver door. With a scan tool, clear PPS DTC (B0071 or B0074). While continuing to keep the doors closed, wait 60 seconds with the ignition OFF. DO NOT operate any functions in the vehicle during this time. Verify that the PPS does not have any DTCs. If PPS DTCs exist, please perform the necessary repair. With the scan tool, clear DTC B0081. Disclaimer Page 7546 Vehicle Zoning Strategy Truck Zoning Page 7609 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. A/T Controls - DTC P1825/P182E or P1915/MIL ON Control Module: All Technical Service Bulletins A/T Controls - DTC P1825/P182E or P1915/MIL ON INFORMATION Bulletin No.: 08-07-30-020E Date: March 03, 2010 Subject: Diagnostic Information for MIL Illuminated with DTC P1825, P182E or P1915 Found Current or as History Code in TCM, No PRNDL Display, Potential No Engine Crank Models: 2006-2009 Cadillac XLR-V 2006-2010 Cadillac STS-V 2007-2009 Cadillac SRX, XLR 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT, STS 2008-2010 Cadillac CTS 2009-2010 Cadillac CTS-V 2006-2010 Chevrolet Corvette 2007-2010 Chevrolet Silverado 2008-2010 Chevrolet Suburban 2009-2010 Chevrolet Avalanche, Tahoe 2010 Chevrolet Camaro, Express 2007-2010 GMC Sierra, Yukon Denali, Yukon XL Denali 2008-2010 GMC Yukon XL 2009-2010 GMC Yukon 2010 GMC Savana 2008-2009 Pontiac G8 2008-2009 HUMMER H2 with 6L50 RPO MYB, 6L80 RPO MYC or 6L90 RPO MYD Automatic Transmission Supercede: This bulletin is being revised to remove the contact information in Step 4 under HISTORY DTC heading and update the models and model years. Please discard Corporate Bulletin Number 08-07-30-020D (Section 07 - Transmission). The following diagnostic information will aid the technician if the MIL is illuminated with DTC P1825, P182E or P1915. The DTC may be found current or as a history code in the TCM along with a no PRNDL display and the potential for no engine crank. 1. Use the Tech 2(R) to capture and record Freeze Frame/Failure Data for all DTCs set. Review the data to determine: - Vehicle speed, commanded gear, transmission temperature, throttle position, transmission ratio, transmission input and output speed sensor RPM when DTC set (use to attempt to duplicate failure) - IMS A/B/C/P and IMS state 2. Using the Tech 2(R), navigate to transmission data and scroll down to IMS. With the ignition ON and the engine OFF, observe the IMS A/B/C/P switch states and IMS states for each shift lever detent position. The chart following this list shows the correct states. 3. If all IMS readings are normal, monitor the PNP status in the engine data list during DTC setting to isolate a possible open or short to ground on the dedicated PNP signal between the TEHCM and the ECM. 4. If the vehicle is a 2009 CTS, STS or SRX, proceed to Step 5 in the History DTC section below before continuing with any additional evaluations. 5. If all IMS and PNP readings are normal, the condition is intermittent in nature and determination of the defective component will be made based on freeze frame data and previous repair history or warranty data. Proceed to History DTC below. If the readings are not as specified above, the fault is still active. Proceed to the Active DTC section below to determine which component(s) is defective. Page 22267 Page 8993 Engine Control Module X2 (Pin 31 To 73) Page 7570 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 22519 Seat Heater: Service and Repair Driver Seat and Passenger Seat Cushion Heater Replacement Driver Seat and Passenger Seat Cushion Heater Replacement Page 6984 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity A/C - Control Module A/C Indicator Blinking Control Module HVAC: All Technical Service Bulletins A/C - Control Module A/C Indicator Blinking Bulletin No.: 07-01-38-006 Date: August 20, 2007 INFORMATION Subject: Information For Vehicles with HVAC Control Module A/C Indicator Blinking Due to Low Battery State of Charge Models: 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon XL with Manual Temperature Control HVAC System (RPO CJ3) An Air Condition (A/C) button on the Heating, Ventilation and Air Conditioning (HVAC) control module may blink when the A/C system is activated. The blinking indicator will turn to a solid light after cycling the A/C button or ignition key. This condition may be caused by a low battery state of charge on a PREVIOUS ignition key cycle. This condition may be due to situations were an unsold vehicle is parked for long periods of time as part of a dealership's unsold inventory. The A/C indicator begins to flash if the battery voltage falls below 9.5 volts. The low voltage condition may occur during an engine crank or if the vehicle is parked and a normal battery state of charge is not maintained. If the A/C indicator continues to blink, use the Tech 2(R) to help determine the cause. Connect the Tech 2 and build the vehicle. Select Powertrain. Select Engine Control Module (ECM). Select Data Display. Select Cooling/HVAC data. Make sure that there has been an A/C request signal. History should indicate any causes. If necessary, refer to SI for further information on HVAC system diagnostic procedures. Page 16909 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 7518 Spark Plug: Testing and Inspection Spark Plug Inspection 1. Verify that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. 2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: * Spark plug fouling-Colder plug * Pre-ignition causing spark plug and/or engine damage-Hotter plug 3. Inspect the terminal post (1) for damage. * Inspect for a bent or broken terminal post (1). * Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should not move. 4. Inspect the insulator (2) for flashover, carbon tracking, or soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: * Inspect the spark plug boot for damage. * Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. 5. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). Page 5080 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 13558 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Diagrams Pedal Positioning Switch: Diagrams Adjustable Pedal Connector End Views I/P Multifunction Switch Assembly Page 16100 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 5380 Page 23132 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 12524 Shift Solenoid: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 4956 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 13532 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Important: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Important: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J 35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors: Page 21840 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 7544 Page 16085 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 16187 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Locations Discharge Air Temperature Sensor / Switch: Locations HVAC Component Views Upper Front Air Temperature Sensors (CJ2) 1 - Air Temperature Sensor - Upper Left 2 - Air Temperature Sensor - Upper Right HVAC Module Page 7760 Body Control Module (BCM) X2 Page 9383 Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Fuel Level Sensor Replacement (Regular Cab w/34 Gal Tank) Removal Procedure 1. Remove the fuel tank module. 2. Disconnect the fuel level sensor wiring pigtail electrical connector (1) from the module cover. 3. Remove the fuel level sensor wiring pigtail from under the module clip (2). 4. Gently push in the fuel level sensor retainers (1), disengaging them from the module reservoir. Page 20903 Note Using the punch and hammer, strike the rounded end of the roll pin to loosen the roll pin. The head of the roll pin should protrude from the handle housing. Remove the roll pin with pliers as shown in the illustration. 3. Using a punch, hammer, and pliers, remove the roll pin from the inside door handle. 4. Discard the roll pin. 5. Install the new roll pin that is included in the door handle kit, P/N 88880051. 6. Install the front side door inside handles. Refer to Front Side Door Inside Handle Replacement in SI. Rear Side Door Inside Handle Replacement 1. Remove the driver and passenger rear side door inside handles. Refer to Rear Side Door Inside Handle Replacement in SI. 2. Place rear side door inside handles on a work bench. Note Using a punch and hammer, strike the rounded end of the roll pin to loosen the roll pin. The head of the roll pin should protrude from the handle housing. Remove the roll pin with pliers as shown in the illustration. 3. Using a punch, hammer, and pliers, remove the roll pin from the inside door handle. 4. Discard the roll pin. Page 6260 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor from the cylinder head. Installation Procedure Notice: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, Page 21398 Front Floor Console Replacement (without RPO SLT) Front Floor Console Replacement (without RPO SLT) Page 5222 Fan Shroud: Service and Repair Engine Coolant Fan Lower Shroud Replacement Engine Coolant Fan Lower Shroud Replacement (Mechanical) Removal Procedure 1. Remove the cooling fan. 2. If equipped with engine oil cooler, remove the oil cooler hose clip from the lower fan shroud. 3. Lift the lower fan shroud up in order to disengage the fan shroud from the retaining clips on the radiator. Installation Procedure 1. Install the lower fan shroud and ensure it is centered over lower radiator support. 2. If equipped with the engine oil cooler, Install the oil cooler hose clip to the lower fan shroud. 3. Install the cooling fan. Page 18467 Evaporator Core: Service and Repair Air Conditioning Evaporator Core Replacement Removal Procedure 1. Remove the HVAC module. 2. If equipped remove the heat stakes (1) from the HVAC module (2) with a screw driver and a hammer. 3. Disconnect all wiring connections from blower motor, blower motor control module and sensors. Also, remove all wiring from retainers before removal. 4. If equipped remove the screws from the HVAC module assembly. 5. Remove the evaporator cowl gasket from the evaporator. 6. Separate the upper HVAC module assembly (2) from the lower HVAC module assembly (1) Page 1003 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 8481 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 10092 7. Remove the fuel pipe bracket nut from the bellhousing stud. 8. Remove the fuel line clip (1) from the bracket on the automatic transmission. 9. If equipped with 4-wheel drive (4WD), remove the fuel hose/pipe clip from the bracket on the transfer case. Page 20051 Speaker: Service and Repair Front Upper Speaker Replacement Front Upper Speaker Replacement Radio Front Floor Console Speaker Replacement Radio Front Floor Console Speaker Replacement Page 2769 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 5079 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 10238 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Discharge Hose Replacement (With RPO Codes LY2, LMF, L76 and L92) Hose/Line HVAC: Service and Repair Discharge Hose Replacement (With RPO Codes LY2, LMF, L76 and L92) Discharge Hose Replacement (LY2, LMF, L76 and L92) Tools Required J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the discharge hose mounting bolt (2) from the A/C compressor. 3. Remove the discharge hose (1) from the A/C compressor. 4. Remove the upper radiator baffle. 5. Remove the discharge hose nut from the condenser. 6. Remove the discharge hose from the condenser. 7. Disconnect the electrical connector from the A/C recirculation switch. 8. Remove the discharge hose from the vehicle. 9. Discard all of the used sealing washers. Cap the system openings. Installation Procedure 1. Install the discharge hose (1) to the vehicle. 2. Connect the electrical connector to the A/C recirculation switch. Page 24213 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 19463 Method 1 Method 2 Page 9018 Page 7218 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 1941 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 24503 2. Remove the front compartment side sight shield on the passenger's side of the engine compartment (1). Refer to Front Compartment Side Sight Shield Replacement in SI. Note The underhood fuse block is located in the engine compartment on the passenger side of the vehicle. Refer to Underhood Fuse Block in the Owner's Manual for fuse information. 3. Locate the underhood bussed electrical center (UBEC) (2). 4. Remove the UBEC cover (2) and locate the WSW/HTR 60 amp heated windshield washer fuse. 5. Remove the WSW/HTR 60 amp heated windshield washer fuse (3) using pliers. 6. Discard the WSW/HTR 60 amp heated windshield washer fuse (3). 7. Refer to Windshield Washer Solvent Heater Removal in this bulletin. After completing the Windshield Washer Solvent Heater Removal service procedure, proceed to step 8 in this section of the bulletin. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI. 9. Test the operation of the windshield wiper system. 1. Ensure the wiper system functions in low and high positions. 2. Verify that the windshield wiper/washer switch functions. The windshield wiper system should provide wiper fluid to the windshield. 3. Verify that the DIC does not display the following message, "HEATING WASH FLUID WASH WIPES PENDING". 10. Install the front compartment side sight shield on the passenger's side of the engine compartment (1). Refer to Front Compartment Side Sight Shield Replacement in SI. 11. Secure the UBEC cover on the UBEC. 12. Close the hood. 13. Make a copy of the Owner Manual Supplement, located at the back of this bulletin, and place it in the glove box. Page 19718 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Page 8172 Engine Control Module: Connector Views Engine Control Module Connector End Views Engine Control Module X1 Page 9479 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 20039 Speaker - Left Rear (Regular Cab) A/T Shift Lock Control Solenoid Page 2111 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Diagrams Throttle Body: Diagrams Engine Controls Connector End Views Throttle Body Page 18662 Solar Sensor: Diagrams HVAC Connector End Views Ambient Light/Sunload Sensor Assembly Specifications Brake Shoe: Specifications Replace the shoe and lining assemblies when the thickness of any lining is worn within 0.72 mm (0.030 in) of the shoe. Replace riveted shoe and lining assemblies when the lining is worn to within 0.76 mm (0.030 in) of any rivet head. Always replace shoe and lining assemblies as a complete axle set. Page 13757 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 6577 Page 5717 Body Control Module (BCM) X7 Page 20362 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 8746 Body Control Module: Locations Data Communication Component Views Behind the I/P 1 - Body Control Module (BCM) 2 - Auxiliary Body Control Module (XBCM) (Export) Below the I/P Page 14030 Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Metric) Page 1974 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 6781 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 11632 Ignition Control Module: Diagrams Engine Controls Connector End Views Ignition Control Module (ICM) Page 17857 Page 2475 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 21491 2. Cycle the sunshade up and down 15-20 cycles. This should engage the detent spring. 3. Repeat the procedure on the second visor. If the above steps fail to resolve the condition, refer to diagnostic procedures in SI to correct the condition. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10091 Evaporative Emissions Hose: Service and Repair Evaporative Emission (EVAP) Hoses/Pipes Replacement - Engine/Chassis (Extended Cab - w/8 Ft Bed) Evaporative Emission Hoses/Pipes Replacement - Engine/Chassis (Extended Cab - w/8 Ft Bed) Removal Procedure Important: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. 3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. Page 1807 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 16426 X305 Inline Harness Connector End Views X305 Body Harness to Passenger Seat Harness (AN3) Page 24660 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 11888 Knock Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 3443 Power Window Switch: Service and Repair Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Front Side Door Window and Rear Side Door Window Switch Replacement (with DL8 and without SLT) Page 7101 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 22483 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 20893 Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement (Extended Cab) Rear Side Door Outside Handle Replacement (Extended Cab) Page 3006 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 12708 3. Use a small flat-blade tool to remove the dress cover. 4. Slide the dress cover forward and off of the connector. Page 6710 Page 7294 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 12809 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 3197 1 - Window Switch - Right Rear (A31) 2 - Inflatable Restraint Side Impact Sensor (SIS) - Right Rear (ASF) 3 - Door Latch Assembly - Right Rear 4 - Speaker - Right Rear Door 5 - Window Motor Right Rear (A31) Page 15477 11. Remove the park brake cable from the vehicle. Installation Procedure 1. Install the park brake cable to the vehicle. 2. Install the brake shoes. Ensure the locking tabs on the cable conduit are fully engaged into the rear axle bracket. Page 7943 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 21856 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 11369 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 7350 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 13989 Control Valve Body Spring, Bolt, Bore Plug and Retainer Identification Chart (Inch) Disclaimer Page 1962 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 16974 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 23555 All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system. Locations Steering Angle Sensor: Locations Antilock Brake System Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch Page 11276 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 1052 3. Position the engine wiring harness lower electrical connector and engage the retainer (3) securing the lower connector (4) to the ECM. 4. Position the engine wiring harness upper electrical connector and engage the retainer (2) securing the upper connector (1) to the ECM. 5. Connect the negative battery cable. 6. If a NEW ECM was installed, program the ECM. Refer to Refer to Programming and Relearning.. See: Testing and Inspection/Programming and Relearning Page 4250 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Snap In Style) Tire Pressure Indicator Sensor Replacement (Snap In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. 3. Dismount the tire from the rim. Important: When servicing the tire pressure sensor always use a new Schrader(R) tire pressure monitor (TPM) and a new TORX screw during installation. 4. Remove the TORX screw (1) from the tire pressure sensor (2) and pull it straight off the tire pressure valve stem (3). Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 5. Remove the tire pressure valve stem by pulling it through the rim. Installation Procedure Page 17106 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 11649 Camshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 3130 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 8558 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 7011 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 12098 cover up until the dress cover releases. Repeat this procedure for the other locking tab. 4. Once the front 2 locks are unlocked, lift the front of the dress cover and pull it forward. Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA releases. Gently pry the TPA out of the connector. Important: Be careful not to angle or rock the J 38125-21 tool when inserting it into the connector or the tool may break. 6. Insert the J 38125-21 (GM P/N 15381651-2) tool into the round canal between the terminals cavities at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Follow the steps below in order to repair Micro 64 connector terminals. The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time. After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 1. Cut the wire as close to the damaged terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. Page 17385 X325 Inline Harness Connector End Views X325 Passenger Seat Harness to Passenger Seat Jumper Harness (AN3) A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Page 12911 6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (367A). 7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A). 8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394). Installation Procedure 1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395). Page 3034 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 10387 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 22011 1. Route the end of the drain hose through the access hole and down the inner side panel, right or left side, as needed. 2. Install the hose clip to the door frame securing the drain hose to the vehicle, right or left side, as needed. 3. Connect the rear drain sunroof hose to the sunroof module rear spigot, right or left side, as needed. 4. Install the headliner. Page 7203 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 4985 4L60-E/4L65-E/4L70-E - Automatic Transmission Control Module: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Transmission Control Module (TCM) 1 - Transmission Control Module (TCM) Page 16971 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 2833 Camshaft Position Sensor: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 18468 7. Remove the evaporator core (1) from the upper HVAC module assembly (2). Installation Procedure Important: If replacing the evaporator core, add the refrigerant oil to the evaporator core. Refer to Refrigerant System Capacities. 1. Install the evaporator core (1) to the HVAC module assembly (2). 2. Install the upper HVAC module assembly (2) from the lower HVAC module assembly (1) 3. Install the evaporator cowl gasket to the evaporator. Notice: Refer to Fastener Notice. 4. Install the screws to the HVAC module assembly. Tighten the screws to 2 N.m (18 lb in). 5. Install the HVAC module assembly. Page 14811 Shift Solenoid 3 (SS3) Page 24583 Washer Fluid Level Switch: Service and Repair Washer Solvent Container Level Sensor Replacement (Chevrolet) Page 13550 9. Remove the terminal position assurance (TPA) by inserting a small flat-bladed tool into the small slot in the end of the slider and pushing on the TPA until it comes out of the connector. When the TPA exits the opposite side of the connector, gasp the TPA and pull it completely out of the connector. 10. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 11. Insert the J 38125-560 (GM P/N 15314260) into the 2 triangular cavities on each side of the terminal at the front of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 12. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Terminal Replacement Procedure Page 11792 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Page 9908 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 21536 Page 12288 Page 14779 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. OnStar(R) - Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Page 18294 Cabin Temperature Sensor / Switch: Service and Repair Inside Air Temperature Sensor Replacement Removal Procedure 1. Remove the left windshield garnish molding. 2. Remove the left center pillar assist handle. 3. Remove the center pillar garnish molding. 4. Remove the left sunshade. 5. Gently pull down the headliner. 6. Disconnect the electrical connector from the inside air temperature sensor. 7. Partially remove the inside air temperature sensor from the headliner. 8. Remove the sensor grille from the inside air temperature sensor. 9. Remove the inside air temperature sensor from the headliner. Installation Procedure 1. Install the new sensor grille to the headliner. 2. Install the inside air temperature sensor to the headliner and sensor grille. 3. Connect the electrical connector to the inside air temperature sensor. 4. Install the left sunshade. Page 21130 Endgate Emblem/Nameplate Replacement (Z71) Endgate Emblem/Nameplate Replacement (Z71) Page 24729 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Page 22282 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 6076 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Push To Seat) Delphi Connectors (Push To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). 3. Use the proper pick or removal tool (1) in order to release the terminal. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. See: Testing and Inspection/Component Tests and General Diagnostics Terminal Repair 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. Page 13881 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 23362 Page 8524 Page 4924 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Park Assist System - Inoperative/Lamp ON/DTC's Set Parking Assist Distance Sensor: All Technical Service Bulletins Park Assist System Inoperative/Lamp ON/DTC's Set TECHNICAL Bulletin No.: 08-08-127-001B Date: June 10, 2010 Subject: Park Assist System Inoperative, Service Park Assist Message Displayed on Driver Information Center (DIC), DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 Set (Replace Appropriate Object Sensor or Repair Harness) Models: 2006-2008 Buick Lucerne 2008-2009 Buick Enclave 2006-2008 Cadillac DTS 2007-2009 Cadillac Escalade, SRX 2008-2010 Cadillac CTS 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2009 Chevrolet Traverse 2007-2009 GMC Acadia, Sierra, Yukon, Yukon XL 2007-2009 Saturn OUTLOOK Equipped with Parking Assist (RPO UD7 or UFR) Supercede: This bulletin is being revised to clarify the text in the Condition, Cause and Correction sections and update the Warranty Information. Please discard Corporate Bulletin Number 08-08-127-001A (Section 08 - Body and Accessories). Condition - Some customers may comment on a Service Park Assist message being displayed on the driver information center (DIC). - The technician may observe with a scan tool DTC B1E3A and/or B0954, B0955, B0956, B0957, B0958, B0959, B0960, B0961 set as Current or in History. Cause - This condition may be caused by a malfunctioning object sensor or a circuit fault on the 8 volt reference circuit. Note The 8 volt reference circuit serves all of the object sensors in parallel. A fault anywhere on the circuit or in any single sensor will affect all of the sensors. - When a single sensor malfunctions, the shared 8 volt reference circuit may be compromised, resulting in a DTC for each sensor. Correction Important DO NOT replace all of the object sensors and/or the object alarm module. If normal diagnosis does not reveal any concerns with the park assist system, perform the following diagnostic procedure: 1. Turn OFF the ignition. Note Depending on the model year of the vehicle the park assist system sensors are referred to as: object sensor or object alarm sensor. 2. Disconnect the harness connector at each of the object sensors. For the locations of the object sensors, refer to Master Electrical Component List in SI. 3. Turn ON the ignition, with the engine OFF. Important With all of the object sensor harness connectors disconnected, multiple sensor DTCs will set and will not clear. Ignore these DTCs for now. 4. Clear any DTCs that may be present. Page 2741 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 12540 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 12552 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. * JAE connector have JAE in small letters on their connectors. Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 23329 Page 14273 4. Install the spider assembly (2). 5. Using the appropriate tool, install the retaining ring (1). Important: Position the boot clamp so that it is at the small end of the boot. 6. Install the tripot assembly (1) and the boot clamp (2). 7. Place approximately half of the lubricant (2) in the boot (1) and the remaining half in the tripot housing (3). Important: Pinch the slightly by hand in order to distort it into an oval shape. Page 5247 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Page 5334 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 9613 7. Apply pressure and gently rock the cover until one locking leg is unseated. 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A (GM P/N 12094429) to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. If the terminal is severely bent or damaged, it may be possible on some connectors to push the wire out of the front of the connector instead of Page 12019 powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 12. Reset the TAP values. Refer to Transmission Adaptive Functions (TCM). Page 12570 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Accessories - Tonneau Cover Handle Separates from Latch Truck Bed Cover Latch: Customer Interest Accessories - Tonneau Cover Handle Separates from Latch Bulletin No.: 07-08-66-008 Date: November 06, 2007 TECHNICAL Subject: GM Accessory Soft Tonneau Cover Pull Strap Handle Separates from Latch (Replace Latch Assembly) Models: 2007-2008 Chevrolet Silverado 2007-2008 GMC Sierra, Sierra Denali Condition Some customers may comment that the front and/or rear tonneau cover pull strap handle separates from the tonneau cover latch. This condition typically occurs on the rear pull strap latch. Cause This condition may be caused by a weak slide eyelet (1) on the pull strap latch. Correction Replace the front and rear pull strap latches with the new design latches following the steps below. Open the tailgate. Release the left rear tonneau cover latch by using a screwdriver to slide the broken eyelet on the latch to the right. Flip the rear of the tonneau cover up. Remove the left rear plastic rail end cover from the rear tonneau cover rail. Page 13255 Fluid Pressure Sensor/Switch: Diagrams Automatic Transmission Internal Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch, Wiring Harness Side Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter Power Mirror Position Switch/Sensor: Customer Interest Body - LH/RH Outside Rearview Mirror Glass Shake/Flutter TECHNICAL Bulletin No.: 06-08-64-027I Date: April 12, 2011 Subject: Left or Right Outside Rearview Mirror Glass Shake or Flutter (Relearn Power Mirrors and Replace Mirror, If Necessary) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Yukon, Yukon XL, Yukon Denali All Equipped with Power Folding Mirrors RPO DL3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-08-64-027H (Section 08 - Body and Accessories). Condition Some customers may comment that the left or right outside rearview mirror glass shakes or flutters at normal driving speeds. Cause - The mirror may have been accidentally pushed in manually or obstructed while folding. - The mirror actuator screws may be loose, allowing the mirror to move. - The metal spring may not have enough tension to hold the mirror from moving. Correction Follow the procedure below to correct this condition. 1. The power folding mirrors should be cycled three complete times to relearn the mirror positions. Then perform a road test and check the mirror glass for stability. If stability is not corrected, proceed to Step 2. 2. Remove the mirror glass. Refer to Mirror Face Replacement in SI. 3. Verify the torque on the four retaining screws on the actuator. Tighten Tighten the screws to 1.13-1.6 Nm (10-14 lb in). 4. Bend the metal spring up to increase the tension engagement to the mirror housing 13 mm (1/2 in). 5. Install the glass assembly by pressing firmly, taking care not to allow the spring finger to unseat from its intended track in the mirror housing. Road test the vehicle. If stability is not improved, replace the mirror assembly. Refer to Power Mirror Replacement in SI. Parts Information If replacing the mirror assembly, see Mirror in Group 16.068 of the appropriate Parts Catalog for part numbers and usage. Warranty Information Important Only one Labor Operation should be claimed depending on the actual repair. Electrical - Battery Goes Dead Overnight Body Control Module: All Technical Service Bulletins Electrical - Battery Goes Dead Overnight Bulletin No.: 06-06-03-009 Date: October 19, 2006 INFORMATION Subject: Diagnostic Information on Battery Draw No Start - Body Control Module, BCM Power Timer Models: 2006-2007 Buick Lucerne 2006-2007 Cadillac DTS 2006-2007 Chevrolet Impala, Monte Carlo 2007 Cadillac Escalade, Escalade ESV, Escalade EXT, SRX 2007 Chevrolet Avalanche, Equinox, Tahoe, Silverado, Suburban 2007 GMC Sierra, Yukon, Yukon XL, Denali, Denali XL 2007 Pontiac Torrent When performing normal diagnosis on a battery that has gone dead overnight, a technician may notice that the vehicle has approximately 4.1 amp draw on the system. The draw may be steady or may drop down to a low milliamp reading for 1-2 seconds and then rise back up to the 4.1 amp range. If this amp draw condition is observed, check for aftermarket accessories or an improperly installed GM accessory that is wired into circuit 6815 (orange wire) for courtesy lamps. Anytime aftermarket accessories are installed into the courtesy lamp circuit, it can cause the inadvertent power timer in the body control module (BCM) to keep resetting. The BCM will remain awake and cause the draw of approximately 4.1 amps. When servicing a vehicle with this concern, back out pin 1 of the connector 2 at the BCM and see if the draw goes away. If the draw goes away, check for an aftermarket accessory (Lojack, non-factory DVD system, alarm, etc.) that is improperly installed in circuit 6815. Disclaimer Page 13096 Disclaimer Page 7973 7. The illustration identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J-38125-553 (15315247) tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 6403 5. Slide the fuel level sensor up, in order to remove the sensor from the module slot. Installation Procedure 1. Position the fuel level sensor over the slot in the reservoir and slide the sensor down into the slot. Page 6585 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 22944 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 8146 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 22552 Seat Latch: Service and Repair Rear Seat Latch Replacement (Extended Cab with A68) Rear Seat Latch Replacement (Extended Cab with A68) Page 13602 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 4706 28. Connect the control port injector module (1). 29. Connect the following electrical connectors: * The A/C compressor clutch (2), if equipped * The A/C pressure switch (1), if equipped 30. Install the fuel pipes/hoses. Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Temperature Versus Resistance Page 8590 2. Slide the lever lock forward while pressing down on the lever lock release tab. 3. The lever should be in the full forward position. Page 24725 2. While depressing the lock, pull the lever over and past the lock. 3. Disconnect the connector from the component. Page 569 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 21459 Page 21652 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Page 15169 Wheel Speed Sensor (WSS) - Left Front (JH6/JH7) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Left Rear (JL4) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Wheel Speed Sensor (WSS) - Right Front (JL4/JF3/JF7) Page 8063 Engine Control Module: Locations Engine Controls Component Views Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Page 22981 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 23157 Front Bumper Impact Bar Replacement (Chevrolet) Front Bumper Reinforcement: Service and Repair Front Bumper Impact Bar Replacement (Chevrolet) Front Bumper Impact Bar Replacement (Chevrolet) Page 22564 Important: You may directly apply 16 volts to the vertical motor terminals to unlock the lead tilt adjuster screw from the stop. Refer to Power Seat Connector End Views in SI. ^ If the rear vertical motor is locked, tap the end of the seat track bracket (1) while toggling the rear of the seat switch up and down with the aid of an assistant. ^ If the front vertical motor is locked, tap the front of the seat track bracket (1) while toggling the front seat switch up and down with the aid of an assistant. 5. Move the front seat to the full forward position. 6. Position the rear of the seat halfway up to gain access to the rear tilt seat adjuster stop. For Buick and Cadillac Models, unhook the rear seat trim cover from the rear seat track bar to gain access the rear lead tilt adjuster screw. 7. Locate the rear lead tilt adjuster screw and the old washer stop (1), then install the new stop (2), P/N 25910191 as shown above. For Buick and Cadillac Models, hook the rear seat trim cover to the rear seat track bar. 8. Position the front seat track to the full rear position. 9. Position the front of the seat halfway up to gain access to the front tilt seat adjuster stop. 10. Located the front lead tilt adjuster screw and the old washer stop, then Install a new stop, P/N 25910191 as previously in Step 7. 11. Cycle the seat to the full tilt up and down positions three complete cycles. This cycling will seat the new stops. 12. Verify that the condition has been fixed. 13. Repeat steps 5-12 for the opposite front seat. 14. Disconnect the battery charger from the vehicle. 15. Close the hood. Page 6242 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 20902 Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverage Adjustments are displayed in the Applicable Warranties section. Parts Information Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Service Procedure Note Replace door handle levers if signs of peeling are present. Note The handle kit contains two door handle levers, replace both sides. Front Side Door Inside Handle Replacement 1. Remove the driver and passenger front side door inside handles. Refer to Front Side Door Inside Handle Replacement in SI. 2. Place front door inside handles on a work bench. Page 6423 Fuel Tank Pressure Sensor: Diagrams Engine Controls Connector End Views Fuel Tank Pressure (FTP) Sensor Page 9781 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 2259 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 9925 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 6892 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 12997 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal Fuel Pressure Gage Installation and Removal Tools Required CH-48027 Digital Pressure Gage Installation Procedure Caution: Refer to Gasoline/Gasoline Vapors Caution. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Connect the CH-48027-1 (1) to the CH-48027-2 (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027, refer to the manufacture's directions. Removal Procedure Page 11098 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 13821 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 7059 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 6790 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 15752 1. Install the appropriate mega fuse (2). Notice: Refer to Fastener Notice. 2. Install the upper mega fuse nut (1), if necessary. Tighten the nut to 9 N.m (80 lb in). 3. Install the auxiliary battery positive cable to the fuse studs. 4. Install the generator battery jumper cable terminal (2) to the fuse stud. 5. Install the generator battery jumper cable to fuse nut (3). Tighten the nut to 9 N.m (80 lb in). 6. Install the auxiliary battery positive cable nut (1) to the mega fuse holder. Tighten the nut to 9 N.m (80 lb in). Page 12646 Emissions - MIL ON/DTC P0446 Stored In ECM Canister Purge Control Valve: All Technical Service Bulletins Emissions - MIL ON/DTC P0446 Stored In ECM TECHNICAL Bulletin No.: 02-06-04-037I Date: September 16, 2010 Subject: Check Engine Light On, Fuel Tank Hard to Fill, DTCs P0442, P0446, P0455 or P0449 Set (Replace Evaporative Emission (EVAP) Vent Valve Solenoid Assembly and Add/Relocate Filter Box Using Service Kit) Models: 1999-2007 Chevrolet Silverado (Classic) Models 1999-2007 GMC Sierra (Classic) Models 2007-2010 Chevrolet Silverado Models (Including Hybrid) 2007-2010 GMC Sierra Models (Including Hybrid) Supercede: This bulletin is being revised to add the 2010 model year and to include the Hybrid models. Please discard Corporate Bulletin Number 02-06-04-037H (Section 06 - Engine/Propulsion System). Condition Some customers may comment about the check engine light being illuminated. They may also comment that their vehicle is difficult to fill with fuel or when filling, the pump continuously shuts off before the tank is full. When checking the vehicle for DTCs, the ECM may report one or more of the following DTCs set as current or in history: P0442, P0446, P0449 or P0455. Cause The EVAP canister vent solenoid (CVS) valve draws fresh air into the system through a vent. Under certain operating conditions, dirt and dust intrusion into the EVAP CVS fresh air intake/venting system, may result in restricted air flow. Under certain operating conditions, water, if ingested into the EVAP CVS fresh air intake/venting system, may reach the CVS valve causing corrosion in the CVS valve, and may cause restrictions in the fresh air intake path, when the valve is in the closed position. Correction (1999-2007 Classic/Old Style Models) After following the published SI diagnostics and determining that the EVAP canister vent valve is the cause of the MIL light, replace the existing EVAP canister vent valve assembly with a new assembly. This new assembly is a sealed unit that is designed to be vented through a remote filter box. To ensure correct installation, follow the procedures below. Important DO NOT replace the EVAP canister assembly for this concern unless it fails the leak test. 1999-2003 Model Year (Use Service Kit P/N 19207762) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector, if equipped. 3. Disengage the two vent valve pipe clips securing the pipe to the underbody. Remove the clips from the underbody and discard. 4. Disconnect the vent valve pipe at the EVAP canister. 5. Remove and retain the EVAP canister vent valve bracket mounting bolt. 6. Remove the complete EVAP canister vent valve assembly with bracket attached and discard. Page 21851 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Page 1906 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 11542 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 5269 Diagrams Pedal Positioning Switch: Diagrams Adjustable Pedal Connector End Views I/P Multifunction Switch Assembly Page 7763 Body Control Module (BCM) X5 Page 18752 Page 23569 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 3889 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 2132 Page 19746 Navigation Software Update Procedure: Use the following procedure to update the Navigation Radio software using the Nav Software Update Disc P/N 25956121 (software version 0B92): This software update can only be used to update the navigation radios specified in this bulletin. DO NOT use this software to update any other vehicle's navigation radio. The Map DVD will be needed to verify the system operation after the software update has been performed. Use the vehicle's existing map DVD. It is recommended to wear latex gloves while performing the software update, to avoid fingerprints on the product and discs. DO NOT stop the engine until all tasks are completed. The software update MUST be performed with the engine RUNNING and the gear position in PARK. If the vehicle is turned off prior to the software update being completed, the process may not work again and a new Navigation Radio may be required. The software update requires using the map DVD slot. The update will not work if the update disc is inserted in the top slot (CD or CD/DVD audio slot). Start the engine, with the gear shifter in PARK - wait until the audio or caution screen is displayed after the opening screen. Press the "NAV" hard key. Press "OK" soft key. Press the "MENU" hard key. Press the "NAV" soft key. Press the "MAP DATABASE INFORMATION" soft key. Press the "CHANGE" soft key. The navigation radio automatically ejects the map DVD. Remove the ejected disc. Load the update disc into the slot located behind the display screen by inserting it partially until the system pulls it in. DO NOT put the disc in the top slot. DO NOT force the display to close. The display screen will remain in the open position until the update is complete. The screen "PREPARING TO LOAD SYSTEM SOFTWARE" will be displayed while the update is loading. The update should take approximately 4 Page 12236 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 13701 11. Install the cable to the steering column bracket. 12. Ensure the tangs fully engage into the steering column bracket. 13. Install the cable end to the steering column ball stud. 14. Install the retainer securing the cable to the steering column. 15. Position the carpet and insulation around the driver area. 16. Install the driver seat. 17. Install the instrument panel knee bolster. 18. Test the transmission for proper shift operation. 19. If all of the gear positions cannot be achieved, adjust the cable. Refer to Range Selector Lever Cable Adjustment. Range Selector Lever Cable Bracket Replacement Range Selector Lever Cable Bracket Replacement Page 20288 8. Install the sensor to the sensor housing. 9. Connect the electrical harness. 10. Install the center rear bumper step pad or the rear bumper impact bar end cap. Page 9364 Crankshaft Position Sensor: Connector Views Engine Controls Connector End Views Crankshaft Position (CKP) Sensor Page 14562 Fluid Pressure Sensor/Switch: Specifications Allison - Automatic Transmission Pressure Switch Manifold (PSM) Logic Pressure Switch Manifold (PSM) Logic Page 7872 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 15896 Reinstalling Terminal 1. In order to reuse a terminal or lead assembly, refer to Wiring Repairs. See: Testing and Inspection/Component Tests and General Diagnostics 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA, and/or the secondary locks. Delphi Connectors (Weather Pack) Delphi Connectors (Weather Pack) Tools Required J-38125 Terminal Repair Kit The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. 4. Insert the Weather Pack(R) terminal removal tool J 38125-10A (GM P/N 12014012-1) into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). Important: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Delphi Connectors (12 Way) Delphi Connectors (12-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2044 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 258 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 6915 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 7095 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 10694 11. Remove the EVAP canister vent solenoid clip (1) from the chassis EVAP line and secure out of the way. 12. Remove the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 13. Disconnect the fuel tank EVAP line quick connect fitting from the chassis line. 14. Disconnect the fuel tank fuel feed line quick connect fitting from the chassis line. 15. Cap the fuel and EVAP lines in order to prevent possible fuel and/or EVAP system contamination. 16. Unclip the inline harness connector from the bracket. 17. Remove the fuel line bracket bolt (1). 18. Remove the fuel/EVAP line clip nut (2). 19. Loosen the brake pressure modulator valve (BPMV) bolts. Slide the BPMV off of the frame and reposition the BPMV without disconnecting the brake lines. 20. Unclip the line assembly from the frame. 21. Remove the fuel/EVAP line clips from the frame and crossmember. 22. Remove the fuel/EVAP line assembly from the vehicle. Installation Procedure Page 18744 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Locations Manifold Pressure/Vacuum Sensor: Locations Engine Controls Component Views Rear of the Engine 1 - Central Sequential Fuel Injection (SFI) Module 2 - Manifold Absolute Pressure (MAP) Sensor 3 G106 4 - Engine Oil Pressure (EOP) Sensor 5 - Ignition Control Module (ICM) 6 - G107 Page 9346 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. Page 179 Door Module: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Page 11293 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 22172 4. Confirm that the switch buttons are free moving, and there is a nominal gap (1) all around its perimeter within the bezel. 5. Reinstall the door trim. Refer to Front Side Door Trim Panel Replacement in SI. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 14718 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 4206 Tire Pressure Sensor: Technical Service Bulletins Tires - Minimizing Damage to TPM Sensors INFORMATION Bulletin No.: 08-03-10-007 Date: May 16, 2008 Subject: Minimizing Damage to Tire Pressure Monitor (TPM) Sensors During Tire Mounting/Dismounting Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Wheel Mounted Tire Pressure Sensors Minimizing Damage To TPM Sensors All GM vehicles now in production and sold in the U.S., as well as many vehicles sold in Canada, feature Tire Pressure Monitoring Systems that have valve stem mounted Tire Pressure Sensors. When dismounting and mounting tires, care must be taken when breaking the bead loose from the wheel. If the tire machines bead breaking fixture is positioned too close to the tire pressure sensor, as the tire bead breaks away from the wheel it may be forced into, or catch on the edge of the tire pressure sensor. This can damage the sensor and require the sensor to be replaced. Care must also be taken when transferring the tire bead to the other side of the wheel rim. As the tire machine rotates and the tire bead is stretched around the wheel rim, the bead can come in contact with the sensor if it is not correctly positioned in relation to the mounting/dismounting head prior to tire mounting/dismounting. This can also cause sensor damage requiring replacement. Procedure Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Page 13934 Transmission Speed Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 17338 Page 17818 Tie Rod: Service and Repair Steering Linkage Outer Tie Rod Replacement Non-Rack & Pinion Steering Linkage Outer Tie Rod Replacement Page 10861 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Engine Controls - Cruise Control Turns Off When Operated PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Cruise Control Turns Off When Operated TECHNICAL Bulletin No.: 09-08-68-001 Date: November 13, 2009 Subject: Cruise Control Turns Off During Operation (Reprogram ECM) Models: 2008-2009 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Silverado 2008-2009 Chevrolet Avalanche, Suburban, Tahoe 2007-2009 GMC Sierra 2008-2009 GMC Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2009 HUMMER H2 Condition On rare occasions, some customers may comment that the cruise control turned off. This typically occurs during operation and while pulling up and releasing both driver door window switches or activating the heated windshield washer fluid system in cold weather conditions with a battery charge below 80%. Cause Cruise control command cancellation is caused by a voltage spike that occurs when the driver door window switches are released or when the heated washer fluid system is activated. Correction A revised calibration has been developed to address this condition. Technicians are to reprogram the ECM with the latest calibrations available. This new service calibration is available on TIS2WEB using the Service Programming System (SPS). Refer to the SPS procedures in SI. SPS may require the technician to select the calibration from the ECM calibration screen. Note This calibration update should only be used when this loss of cruise control condition is experienced. When using a Tech 2(R) or a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. During programming, the battery voltage must be maintained within the proper range of 12-15 volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 16990 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 12453 Automatic Transmission Inline 16-Way Connector End View in SI) and the valve body assembly. If continuity exists, a short to ground is present in the TEHCM and it should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. If there is no continuity, the problem is outside the transmission. Important The bad bit should be consistent with the bad bit identified in Step 2. 3. Connect a 3-amp fused jumper wire between the common pin (Pin A) and pins B, C, D & F in the TEHCM IMS connector (refer to Automatic Transmission Internal Connector End Views in SI). As each circuit (B, C, D & F) is grounded with ignition ON, engine OFF, the Tech 2(R) should display low (L) for the IMS bit. - If any of the A/B/C/P circuits displays high (H) when grounded, the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If Pin F in the PNP Switch Circuit (Tech 2(R) Engine data) displays "In Gear" when grounded, an open exist in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal Pin 3 (refer to Automatic Transmission Inline 16-Way Connector End View in SI) and TEHCM IMS connection Pin F (refer to Automatic Transmission Internal Connector End Views in SI). If there is continuity, the problem is outside the transmission. If there is no continuity, replace the TEHCM. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. Important The bad bit should be consistent with the bad bit identified in Step 2. 4. If the two tests above indicate correct TEHCM operation and the condition still exists, the IMS is faulty and should be replaced. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. 5. Update the TCM calibration file to the latest released on TIS2WEB. Disclaimer Page 1986 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 17053 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Locations Yaw Rate Sensor: Locations Antilock Brake System Component Views Under the Front Seats 1 - Yaw Rate and Lateral Acceleration Sensor (JL4) Page 14052 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 395 - Bore Plug and Solenoid Retainer 396 - TCC PWM Solenoid Valve 397 - Regulator Apply Spring 398 - Isolator Valve 399 - Pump Ball Check Valve - M33 Only Page 11697 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 19111 1 - Door Frame 2 - Window Switch - Left Rear (ABV) 3 - Speaker - Left Rear Door 4 - Inflatable Restraint Side Impact Sensor (SIS) - Left Rear (ASF) 5 - Window Motor - Left Rear (ABV) Right Rear Door (Extended Cab) OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Page 3133 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 1544 1. Install the park brake warning lamp switch. Notice: Refer to Fastener Notice. 2. Install the park brake warning lamp switch bolt. Tighten the bolt to 3 N.m (27 lb in). 3. Connect the park brake warning lamp switch electrical connector. 4. Install the left side instrument panel electrical center/junction block. 5. Connect the negative battery cable. Page 21593 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 12556 View of a typical Micro 64 connector. Depress the lock and pull the lever over and past the lock. Page 582 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Locations Torque Converter Clutch Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 174 Diagrams Auxiliary Input / Output Jack: Diagrams Entertainment/Communication Connector End Views Audio/Video Adapter (U42) Page 14754 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 15516 7. Release the C-clamp. 8. Remove the nut from the stud. 9. Remove the J 26889. 10. Install the master cylinder to the hydraulic booster. 11. Release the park brake and unblock the wheels. Page 7253 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Locations Oxygen Sensor: Locations Engine Controls Component Views Left Side of Engine 1 - Generator 2 - Throttle Body 3 - Transmission 4 - Park/Neutral Position (PNP) Switch 5 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 2 6 - Heated Oxygen Sensor (HO2S) Bank 1 Sensor 1 7 Knock Sensor (KS) - 1 8 - Engine Coolant Temperature (ECT) Sensor 9 - A/C Compressor Clutch (C67/CJ2) Right Side of Engine Page 6580 Page 19041 Seat Belt Height Adjuster: Service and Repair Seat Belt Height Adjuster Replacement - Front Seat Belt Height Adjuster Replacement - Front Page 23018 The body control module (BCM) determines when the cruise control cancel switch is activated. When the normally open cancel switch is closed, the BCM detects the predetermined voltage signal on the cruise control function switch circuit. The BCM sends a GMLAN serial data message to the ECM in order to disengage the cruise control system. The stop lamp switch is mounted on the brake pedal bracket. When the brake pedal is applied, the normally open stop lamp switch closes. The ECM monitors the stop lamp signal circuit through a discrete input and a GMLAN serial data message signal from the BCM indicating the brake status. When both signals indicate the brake pedal is applied, the ECM will disengage the cruise control system. The Cruise Control System will disengage when the cruise control on/off switch is switched OFF. The vehicle speed stored in the memory of the engine control module will be erased when the cruise control On/Off switch is turned OFF, or the ignition switch is turned OFF. The Cruise Control System will disengage when the ECM detects that a driver override function has been active for approximately 60 seconds. When the Cruise Control System has been disengaged, the ECM sends a GMLAN serial message to the instrument panel cluster (IPC) in order to turn OFF the Cruise Engaged indicator, and to the driver information center (DIC) in order to turn OFF the CRUISE SET TO ### message. Cruise Control Inhibited The engine control module (ECM) inhibits the cruise control operation when any of the following conditions exist: * The ECM has not detected a brake pedal activation from the body control module (BCM). * A Cruise Control System DTC has been set. * The vehicle speed is less than 40.2 km/h (25 mph). * The vehicle speed is too high. * The vehicle is in PARK, REVERSE, NEUTRAL, or 1st gear. * The engine RPM is too low. * The engine RPM is too high. * The system voltage is not between 9-16 volts. * The Antilock Brake System (ABS)/Traction Control System (TCS) is active for more than 2 seconds. Page 14880 After the terminal is crimped to the wire perform the following procedure in order to replace Micro-Pack 100 terminals. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the Terminal Removal Procedure. Delphi Connectors (Pull To Seat) Delphi Connectors (Pull To Seat) Tools Required J-38125 Terminal Repair Kit Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. Important: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal out the front of the connector body. Terminal Repair 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. Terminal Installation 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Page 6977 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 14973 3. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller - Light Blue with White Stripe: Brake switch input to power electric brake controller - White: ground - Orange: CHMSL (Center High Mounted Stop Lamp) - not required with most systems 4. After completing the under dash connections to the electric brake controller, open the hood and locate the red wire that is taped to the harness between the underhood electrical center and the driver side front fender. 5. Break the tape on the red/black wire and pull it toward the front of vehicle. 6. Remove the lid from the electrical center. Important Ensure that the ringlets are not interfering with the UBEC cover. 7. Place the terminal on the larger of the two studs at the front of the electrical center and secure with an M8 nut. This is circuit #242 to stud #2, to power the aftermarket trailer brake controller. Important The fuse is already present in the vehicle to power the electrical trailer brake controller system. Auxiliary Power (Applies to All LD & 07-09 HD's Only) Page 9235 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 7290 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips Splicing Copper Wire Using Splice Clips Important: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves. See: Testing and Inspection/Component Tests and General Diagnostics Tools Required Page 21847 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 377 at connector X126 terminal "G" or X115 terminal "B5." Obtain enough Dark Blue 12 gauge wire to run from X126/X115 to the 7-way trailer connector at the bumper. On one end of the Dark Blue wire attach terminal part number 15304732, located in Delphi Tray 8 and insert into X126 "G" or terminal part number 15304720 located in Delphi Tray 19 and insert into X115 "B5." Run the Dark Blue wire in its own conduit along the frame to the 7-way trailer connector at the bumper. Remove circuit 47 from the 7-way trailer connector terminal "C" and tape the bare terminal and attach to the harness. Attach terminal part number 12110853, located in Delphi Tray 4, to the other end of the Dark Blue wire and insert it into the 7-way trailer connector terminal "C." 3. ONLY For Vehicles Equipped with JL1 - The Red/Black wire, circuit 242, must be connected to stud #2 of the 30 Amp fuse of the underhood fuse block. This wire is located between the left fender and the underhood fuse block. Important This procedure will not result in any trailer brake related display messages to be set. However, ITBC diagnostics will continue to function. If an ITBC fault is detected, a "Service Trailer Brake System" message will be displayed on the driver information center (DIC) and an appropriate DTC will be stored in the ITBC module. The operator will still be able to adjust gain and access the "Trailer Gain / Output" display page in the DIC. However, the factory installed ITBC system will not sense a trailer connection and will not provide output to the trailer. 4. Locate the trailer brake control circuits that are looped and taped to the main harness under the instrument panel. 5. Pull the trailering wire harness down. 6. Match the vehicle harness label circuit functions to the trailer brake controller jumper harness functions. Important The color or wires to be joined together may not match. - Dark Blue Wire: switched power from controller to trailer brakes - Red with Black Stripe: fused vehicle power to electrical brake controller Page 6074 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Page 2563 Transmission Position Switch/Sensor: Locations 6L50/6L80/6L90 - Automatic Transmission Automatic Transmission Electronic Component Views Electronic Components Electronic Components 1 - Control Solenoid (with Body and TCM) Valve Assembly 2 - A/Trans Input and Output Speed Sensor Assembly 3 - A/Trans Manual Shift Shaft Position Switch Assembly Page 10614 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Campaign - Front And Rear Chrome Interior Door Handle Technical Service Bulletin # 09239A Date: 100825 Campaign - Front And Rear Chrome Interior Door Handle SPECIAL COVERAGE Bulletin No.: 09239A Date: August 25, 2010 Subject: 09239A - Special Coverage Adjustment - Front and Rear Chrome Interior Door Handle Lever Models: 2007 Cadillac Escalade, Escalade ESV, Escalade EXT 2007 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007 GMC Sierra, Yukon, Yukon XL Equipped with Chrome Interior Door Handles Supercede: The Parts Information section has been revised to include a note that P/N 88880051 is used for the front and rear doors. Step 6 under the Rear Side Door Inside Handle Replacement procedure has also been revised to refer technicians to the Rear Side Door Inside Handle Replacement in SI.Please discard all copies of bulletin 09293, issued July 2010. Condition Some customers of 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles may comment about peeling on the top surface of the front or rear chrome interior door handle(s). A chrome plating irregularity combined with direct sunlight exposure may cause the plating to separate from the top surface of the handle on certain vehicles. Special Coverage Adjustment This special coverage covers the condition described above for a period of 10 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership or mileage. Dealers are to replace the front and/or rear chrome interior door handle levers if signs of peeling are present. The repairs will be made at no charge to the customer. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after July 16, 2010, are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to July 16, 2010, must be submitted to the Service Contract provider. Vehicles Involved Involved are certain 2007 model year Cadillac Escalade, Escalade ESV, Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, Tahoe; GMC Sierra, Yukon, and Yukon XL vehicles built within the following VIN breakpoints: Page 500 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 23104 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 11410 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 11335 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 998 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 7068 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 7369 4. Release the lower wiredress cover locking tab. 5. Release the upper wiredress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 304 Memory Seat Module X6 (AN3) Page 16092 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Tools Required j 45405 Pipe Flaring Tool Kit Caution: Refer to Brake Fluid Irritant Caution. Caution: Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Important: When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the J 45405. * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Important: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 6. Using the pipe cutter included in the J 45405, carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. Page 20280 Parking Assist Distance Sensor: Locations Object Detection Component Views Rear of the Vehicle (X88) 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Backup Lamp - Right Rear 4 - Tail/Stop and Turn Signal Lamp - Lower Right 5 - Object Sensor Right Rear Corner (UD7) 6 - License Lamp - Right 7 - Object Sensor - Right Rear Middle (UD7) 8 Marker Lamp - Tailgate (R05) 9 - Object Sensor - Left Rear Middle (UD7) 10 - License Lamp - Left 11 - Object Sensor - Left Rear Corner (UD7) 12 - Tail/Stop and Turn Signal Lamp - Lower Left 13 Backup Lamp - Left Rear Rear of the Vehicle (Z88) Page 19318 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Page 14073 10. Install the manual detent spring. 11. Install but do not tighten the manual detent spring bolt. 12. Install the transmission fluid pressure switch. 13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body. Notice: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation. 14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten the bolts in the sequence shown to 11 N.m (97 lb in). 15. Ensure that the manual detent spring is aligned properly with the detent lever. Page 24681 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 7941 View of the connector when released from the component. View of another type of Micro 64 connector. Page 4794 4. Loosen the air cleaner housing screws. 5. Lift up the air cleaner housing cover. 6. Remove the air filter element. Installation Procedure 1. Insert the NEW air filter element. 2. Install the air cleaner housing cover. Notice: Refer to Fastener Notice. 3. Tighten the air cleaner housing screws. Tighten the screws to 3 N.m (27 lb in). Page 5383 Page 8893 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 5403 7. Release the tabs that are holding the wiredress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. 9. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 23346 Parking Brake Warning Switch: Diagrams Park Brake Switch Park Brake Switch Page 2276 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 35 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Page 973 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 16262 Fuse Block - I/P X2 Page 14611 Transmission Position Switch/Sensor: Adjustments Park/Neutral Position Switch Adjustment Important: * The following procedure is for vehicles that have not had the park/neutral position (PNP) switch removed or replaced. If the PNP switch has been removed or replaced, refer to Park/Neutral Position Switch Replacement for the proper adjustment procedure. * Apply the park brake. * The engine must start in the park (P) or neutral (N) positions only. * Check the PNP switch for proper operation. If adjustment is required, proceed as follows: 1. Place the transmission range selector in the neutral (N) position. 2. With an assistant in the drivers seat, raise and suitably support the vehicle. Refer to Vehicle Lifting. 3. Loosen the park/neutral position (PNP) switch bolts. 4. With the vehicle in the neutral (N) position, rotate the switch while the assistant attempts to start the engine. 5. Following a successful start, turn the engine off. Notice: Refer to Fastener Notice. 6. Tighten the PNP switch bolts. Tighten the bolts to 25 N.m (18 lb ft). 7. Lower the vehicle. 8. Check the PNP switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. 9. Replace the PNP switch if proper operation can not be achieved. Page 13778 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 10685 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Chassis (Extended Cab) Fuel Hose/Pipes Replacement - Chassis (Extended Cab) Removal Procedure Important: Clean all fuel and evaporative emission (EVAP) lines connections and surrounding areas prior to disconnecting the lines in order to avoid possible fuel and/or EVAP system contamination. 1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Disconnect the engine evaporative emission (EVAP) line quick connect fitting (2) from the chassis EVAP line. 3. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. 4. Cap the fuel rail and EVAP pipes. 5. Raise and support the vehicle. Refer to Vehicle Lifting. 6. Unbolt and reposition the front propeller shaft, if required. Refer to Front Propeller Shaft Replacement. Electrical - Electrical Malfunction/Multiple DTCs Technical Service Bulletin # 08-07-30-021E Date: 100607 Electrical - Electrical Malfunction/Multiple DTCs TECHNICAL Bulletin No.: 08-07-30-021E Date: June 07, 2010 Subject: Loss of High Speed GMLAN Communications, Intermittent No Crank, IP Gage Fluctuation, Intermittent Door Lock Cycling, Intermittent Chime Operation, Various IP Warning Lamps Illuminated, Transmission May Not Shift, Communication DTCs U0073, U0100, U0101, U0102, U0109, U0121 or U0140 Set (Repair Backed Out Terminal in Transmission Harness Connector, Repair Open or Shorted GM High Speed LAN Circuits, Open or Shorted Data Link Resistor, Correct Corrosion or Poor Connections in Various Control Module Connectors) Models: 2007-2010 Cadillac Escalade Models, XLR 2009-2010 Cadillac Escalade Hybrid 2007-2010 Chevrolet Avalanche, Corvette, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Silverado Hybrid, Tahoe Hybrid 2007-2010 GMC Sierra, Yukon Models 2008-2010 GMC Sierra Hybrid, Yukon Hybrid 2008-2009 HUMMER H2 Equipped With 6 Speed 6L80 (RPO MYC) or 6L90 (RPO MYD) or Hybrid Two Mode 2ML70 Automatic Transmission Please Refer to GMVIS Supercede: This bulletin is being revised to update the Parts and Warranty Information. Please discard Corporate Bulletin Number 08-07-30-021D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on any of the following conditions: - Instrument panel cluster (IPC) warning lamps may illuminate. - The transmission may not shift or defaults to 2nd gear. - The door locks may cycle by themselves. - The engine may not crank intermittently. - A driver information center (DIC) message is displayed. - The IPC gages may fluctuate. - Applying the brakes may cause the IPC to become erratic and the chimes to operate simultaneously. Depending on the vehicle, technicians may find one or more of the following High Speed GMLAN Communications DTCs set as Current or History: - U0073: Control Module Communications Bus OFF - U0100: Lost Communication With ECM/PCM - U0101: Lost Communication With TCM - U0102: Lost Communication With Transfer Case Control Module - U0109: Lost Communication With Fuel Pump Control Module - U0121: Lost Communication With ABS Control Module - U0140: Lost Communication With Body Control Module (BCM) Cause These conditions may be caused by, but not limited to, any of the following: - The terminal(s) for the High Speed GMLAN Serial Data Bus has backed out of the 16-way electrical connector to the automatic transmission. - The terminal position assurance (TPA) lock in the transmission 16-way electrical connector is not fully seated. - The High Speed GMLAN Serial Data Bus circuits are open or shorted to ground. - Corrosion in various control module connectors. - Intermittent or poor connections in the inline connectors containing the High Speed GMLAN Serial Data Bus circuits. - The data link resistor is open or shorted. - Water intrusion in various control module connectors. Page 7096 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 9720 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 11722 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Locations Steering Angle Sensor: Locations Shift Lock Control Component Views Steering Column Components Steering Column Components 1 - Turn Signal Multifunction Switch 2 - Ignition Lock Cylinder 3 - Tow/Haul Switch 4 - Steering Angle Sensor 5 - A/T Shift Lock Control Solenoid 6 - Theft Deterrent Control Module 7 - Ignition Switch 8 - Inflatable Restraint Steering Wheel Module Coil Page 7861 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2158 * Check the lock ring for flatness. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gage at 7 points. 13. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement. 14. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced. Installation Procedure 1. Install a NEW fuel tank module O-ring seal onto the fuel tank. Important: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm. 2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank. 3. Lower the module assembly into the tank. 4. Position and install the fuel tank module lock ring. 5. Install the J 45722 to the fuel tank module lock ring. Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Page 16643 The IP harness may be in hard contact with the top rear edge (1) of the park brake assembly. When releasing the park brake pedal with the park brake release lever/handle, the moving part (1) at the end of the park brake release cable may be coming into hard contact with the IP harness. Correction If the symptoms match those listed above, or if a condition is found with one of the circuits running to C1 or C2 of the junction block or to the inline IP-to-body connector (C202), then remove the front driver side door sill plate, driver side body hinge pillar trim panel, left IP outer trim cover and perform the following steps: Visually inspect the IP harness for damage at the park brake pedal assembly (refer to potential damage points in photos - at the side and rear of the park brake assembly). Note that damage may be hidden from view (turned away from you, or covered by electrical tape). Operate the park brake release lever. Is the moving part at the end of the park brake release cable coming into contact and damaging the IP harness? Inspect the IP harness at this point. Note that the damage may be hidden from view (by electrical tape). If damage is found, repair the wiring. Page 17648 10. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. 11. Position the rim so that the valve stem (1) is situated at the 3 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem is situated at the 9 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 21235 Warranty Information Important Implementation of this service bulletin by all dealers requires prior District Service Manager (DVM) (in Canada, the Warranty Manager) approval. Page 12286 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 14832 Page 302 Memory Seat Module X4 (AN3) Page 10780 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 7859 Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (0.25 Cap) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component by pressing down on the connector position assurance (CPA). 2. Use a small flat-bladed tool to release the terminal position assurance (TPA) by inserting the tool in the small recess on the side of the connector and pushing up until the TPA releases from the connector body. The TPA should raise just slightly. Do not try to remove the TPA. Important: The TPA on this connector cannot be removed unless the terminals are removed first. The TPA will come out of the connector body, but only slightly. When the TPA is slightly raised the terminals can be removed. Using excessive force to remove the TPA with the terminals still in the connector will damage the connector. 3. Repeat the process for the other side of the connector. 4. Ensure that the TPA is in the proper position to remove the terminals. Body - Tapping/Clicking/Ticking Noise at Windshield Area Windshield Moulding / Trim: All Technical Service Bulletins Body - Tapping/Clicking/Ticking Noise at Windshield Area TECHNICAL Bulletin No.: 08-08-48-003F Date: April 06, 2011 Subject: Tapping, Clicking or Ticking Noise at Windshield Area (R&R; Right and Left Windshield Side Reveal Moldings to Add Double Sided Tape) Models: 2007-2012 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2012 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2012 GMC Sierra, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-08-48-003E (Section 08 - Body and Accessories). Condition Some customers may comment on hearing a tapping, clicking or ticking noise at the windshield area. This condition occurs more frequently while driving at highway speeds and could be exaggerated on vehicles with front bug guard deflectors. Cause This condition may be caused by air/wind causing the windshield side reveal moldings to move, generating a noise. Correction Remove both windshield reveal moldings, add double-sided tape and re-install the moldings following the steps below: 1. Using tape (1) or a grease pencil, mark the position of the inboard edge (2) of both left and right reveal moldings onto the windshield, following the contour of the molding. 2. Remove the left and right windshield side reveal moldings. Refer to Windshield Side Reveal Molding Replacement in SI. 3. Being careful not to affect the tape or grease pencil marks, clean and prep the glass at the seal interface with Glass Adhesion Promoter, P/N 12378555 (in Canada, use 88901239). Page 121 3. Disconnect the vent valve pipe quick connect from the canister. 4. Either cut the existing valve vent pipe and leave the remaining section of pipe in the vehicle or remove along with the valve. 5. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. 6. Cut back the existing canister pipe approximately 51 mm (2 in) and retain the pipe for use with new valve. 7. Connect the canister pipe quick connect to the canister. 2500 Crew Cab Short Box Shown Below, Other Configurations Similar 1500 Extended Cab Short Box Shown Below, Other Configurations Similar 8. Install the new canister vent valve solenoid to the fuel tank clip or mounting bracket as shown above. The valve port closest to the electrical connector must point towards the canister. 9. Cut bulk 5/8" heater hose to a length of approximately 76 mm (3 in). Install the hose between the solenoid and the canister pipe and secure using clamps. 10. Attach bulk 5/8" heater hose to the vent port and secure using a clamp. Run a length as needed along the frame rail routing to the passenger side area above the transmission. 11. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 12. Remove the transmission heat shield, if necessary. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Reinstall the transmission heat shield. 17. Connect the EVAP canister vent valve electrical connector. 18. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 19. Lower the vehicle. Parts Information Page 6082 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Front Upper Speaker Replacement Speaker: Service and Repair Front Upper Speaker Replacement Front Upper Speaker Replacement Drivetrain - Bump/Clunk Noise at Stop Or From Launch Slip Yoke: All Technical Service Bulletins Drivetrain - Bump/Clunk Noise at Stop Or From Launch TECHNICAL Bulletin No.: 09-04-17-002E Date: January 14, 2011 Subject: Bump Feel/Clunk Noise at Stop or from Launch (Clean/Lubricate Propeller Shaft Slip Yoke Splines) Models: 2007-2008 Chevrolet Avalanche, Suburban 2007-2009 Chevrolet Tahoe 2007-2010 Chevrolet Silverado (New Body Style) with Single-Piece Propshafts 2007-2008 GMC Yukon XL 2007-2009 GMC Yukon 2007-2010 GMC Sierra (New Body Style) with Single-Piece Propshafts All Equipped with 4L60 Automatic Transmission (RPO M30) and 2WD Attention: This bulletin contains a procedure to clean/lubricate the slip yoke splines and replace the slip yoke, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the slip yoke. Supercede: This bulletin is being revised to update the warranty statement. Please discard Corporate Bulletin Number 09-04-17-002D (Section 04 - Driveline/Axle). Condition Some customers may comment that the vehicle has a bump feel or a clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind. Cause This condition may be caused by a slip/stick condition in the interface between the rear propshaft slip yoke and the transmission output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transmission while the vehicle rebounds slightly backward after stopping its momentum and create this condition. Correction Note Do not use the grease from this bulletin for lubrication of the slip yoke splines on 2WD MYC 6 Speed Transmissions or any 4WD vehicles. The output shaft in a 2WD MYC 6 Speed Transmissions or a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transmission or the transfer case and mixing with the fluid inside. The new grease is not compatible with the automatic transmission fluid (ATF) and can cause damage if mixed. Please refer to Corporate Bulletin Number 09-04-21-003B for repairing the bump feel or clunk noise condition on 4WD vehicles. Note A bump feel or noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic. Verify the customer's concern. Clean/Lubricate Slip Yoke Splines 1. Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI. 2. Inspect the rear slip yoke splines on the drive shaft. 3. Clean the slip yoke splines with brake cleaner or equivalent and a shop towel. 4. Assure the yoke is free of rust or other foreign material. 5. Lubricate the slip yoke spline with grease, P/N 19257121 (in Canada, 19257122), using a brush or swab to completely cover the entire spline with a light coating of grease. Tires/Wheels - Rattle Noise from Wheel Or Hub Cap Wheel Fastener: All Technical Service Bulletins Tires/Wheels - Rattle Noise from Wheel Or Hub Cap TECHNICAL Bulletin No.: 07-03-10-012D Date: April 12, 2011 Subject: Rattle Noise from Wheel or Hub Cap While Driving, Loose Wheel Nut Caps or Wheel Nut Caps May Not Tighten on Wheel Nuts (Inspect/Replace Wheel Nut Caps As Necessary) Models: 2007-2012 Chevrolet Express, Silverado, Suburban 1500, 2500 and 3500 Series 2007-2012 GMC Savana, Sierra, Yukon XL 1500, 2500 and 3500 Series with 8 Lug Wheel Nut Center Caps (RPOs NX7, NZ7, PY0, PY2, PY9, P03, P25, QB5, QC1, QR5, Q9A) Supercede: This bulletin is being revised to update the model year information. Please discard Corporate Bulletin Number 07-03-10-012C (Section 03 - Suspension). Condition Some customers may comment on a rattle noise from the wheel or hub cap while driving. Other customers may comment on loose wheel nut caps or caps that may not tighten on the wheel nuts. Cause Depending on the generation of the wheel caps, the issue may be overtorqued wheel nut caps or may be caused by the lack of internal threads inside the wheel nut caps. The wheel nut cap (1) is correctly threaded. The wheel nut cap (2) shows the insufficient threads. Correction Important The wheel nut caps are serviced separately from the center wheel hub cap for most hub caps. Refer to the GM electronic parts catalog (EPC) for details. Inspect each wheel nut cap and replace as necessary using the steps below. 1. Remove the wheel hub cap from the vehicle. 2. Place the front of the wheel hub cap down on a protected clean work bench being careful not to scratch or damage the hub cap surface. 3. Inspect all the wheel nut caps, marking any bad wheel nut caps. Page 8475 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 12246 View of typical connector. View of connector in released position. 1. Locate the assist lever at the back of the connector. Move the assist lever to the rear position. 2. Disconnect the connector from the component. Page 15329 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Caution: Refer to Brake Fluid Irritant Caution. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice. Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance - oil-based substance - Layered appearance - silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (JD9, JF3, JF7) Master Cylinder Replacement (JH6, JH7) * Front Brake Hose Replacement (JD9, JF3, JF7) Front Brake Hose Replacement (JH6, JH7) * Rear Brake Hose Replacement (Caliper - JD9) Rear Brake Hose Replacement (Caliper - JH6, JH7) Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4) Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) Rear Brake Hose Replacement (Frame to Axle JH6, JH7) * Front Brake Caliper Replacement (JD9, JF3, JF7) Front Brake Caliper Replacement (JH6, JH7) * Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JH6, JH7) * Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Brake Pressure Modulator Valve Replacement (JH6, JH7) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (JD9, JF3, JF7) Master Cylinder Replacement (JH6, JH7) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (JD9, JF3, JF7) Master Cylinder Reservoir Replacement (JH6, JH7). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (JD9, JF3, JF7) Front Brake Hose Replacement (JH6, JH7) * Rear Brake Hose Replacement (Caliper - JD9) Rear Brake Hose Replacement (Caliper - JH6, JH7) Rear Brake Hose Replacement (Frame to Axle - JD9, JF3 w/JL4) Rear Brake Hose Replacement (Frame to Axle - JF3 w/o JL4, JF7) Rear Brake Hose Replacement (Frame to Axle JH6, JH7) * Front Brake Caliper Overhaul (JH6, JH7) or Front Brake Caliper Replacement (JD9, JF3, JF7) Front Brake Caliper Replacement (JH6, JH7) * Rear Brake Caliper Overhaul (JH6, JH7) or Rear Brake Caliper Replacement (JD9) Rear Brake Caliper Replacement (JH6, JH7) * Brake Pressure Modulator Valve Replacement (JD9, JF3, JF7) Brake Pressure Modulator Valve Replacement (JH6, JH7) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, Page 23643 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 1035 Important: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, 1 is for the salmon and green splice sleeve, 2 is for the blue splice sleeve, and 3 is for the yellow splice sleeve. Page 12211 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 6523 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 21925 Power Seat Control Module: Service and Repair Memory Seat Control Module Replacement Air Conditioning - Diagnose A/C Low Pressure Switch Low Pressure Sensor / Switch: Technical Service Bulletins Air Conditioning - Diagnose A/C Low Pressure Switch INFORMATION Bulletin No.: 04-01-38-010A Date: January 21, 2010 Subject: Diagnostic Information to Accurately Diagnose A/C Low Pressure Switch Using Kent Moore Special Tool GE-47742 Models: 2002-2006 Cadillac Escalade, Escalade EXT 2003-2006 Cadillac Escalade ESV 1999-2007 Chevrolet Silverado 2000-2006 Chevrolet Suburban, Tahoe 2002-2007 Chevrolet Avalanche 1999-2007 GMC Sierra 2000-2006 GMC Yukon, Yukon XL 2001-2006 GMC Yukon Denali XL 2001-2007 GMC Sierra Denali, Yukon Denali XL 2003-2008 HUMMER H2 with Air Conditioning Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 04-01-38-010 (Section 01 - HVAC). Currently, technicians cannot accurately determine the air conditioning (A/C) low pressure switch open/close pressure point by measuring pressure at the low side service port. This is because the evaporator is between the low side service port and the A/C low pressure switch. Correlating pressures measured at the low side service port to actual pressures at the A/C low pressure switch port is difficult because of the multiple variables that impact pressure drop across the evaporator. Providing a pressure range that would take into account all these variables would result in a pressure range that would be too broad to be useful for diagnostic purposes. Kent Moore special tool GE-47742 will allow technicians to monitor the actual pressures at which the A/C low pressure switch opens and closes under actual operating conditions. Technicians are to use the following steps to install and use Kent Moore special tool GE-47742 to measure A/C low pressure switch opening and closing pressures: 1. Disconnect the wire harness from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Install the A/C low pressure switch, using the threaded port with an O-ring, onto special tool GE-47742. 4. Install special tool GE-47742, with the A/C low pressure switch attached, onto the accumulator. Important Removing the seal from the A/C low pressure switch wire harness connector is required. Failure to remove the seal before plugging it into the switch will lead to misdiagnosis. The "plunger effect" of plugging the connector with a seal into the A/C low pressure switch induces a pressure on the back side of the switch. This pressure will skew the opening/closing characteristics of the switch 34-69 kPa (5-10 psi) until the pressure bleeds off. The time required for the connection induced pressure to bleed off can be 20 minutes or longer. 5. Remove the seal from the A/C low pressure switch wire harness connector. 6. Connect the wire harness, without the seal, to the A/C low pressure switch. 7. Connect the low side service hose from the ACR2000(R) or GE-48800 to the service port on special tool GE-47742. 8. Connect a Tech2(R) to the vehicle. 9. Start the vehicle and maintain an engine speed of 1500 RPM. Set the HVAC controls as follows: - Set the A/C control switch to ON. - Set the mode control switch to A/C and engage recirculation mode. - Set the blower motor speed to LOW. - Set the temperature control to full cold. - Set the auxiliary blower motor speed to LOW. If equipped. - Set the auxiliary temperature control to full cold. If equipped. - The vehicle must be operating with no sun load (in the shade). 10. Use the Tech2(R) to determine the A/C low pressure switch status and the ACR2000(R) or GE-48800 to determine the A/C low side pressure. Simultaneously monitor the switch status and the pressure at which the A/C low pressure switch opens and closes. The Tech2(R) will display switch status as "Normal" for Closed and "Low Pressure" for Open. A properly operating switch should open between 138-172 kPa (20-25 psi) Page 2654 Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. The release tab is located on the top of the wiredress cover. View of connector in released position. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress Page 4563 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Page 16986 View of the female half of the connector with male terminals. 3. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. View of the female half of the connector with male terminals. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch Page 575 pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. Terminal Repair Procedure The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals. 1. Cut the wire as close to the terminal as possible. Important: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible. 4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly. 5. Place stripped wire into terminal. 6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator. Terminal Replacement Procedure Navigation Radio - Volume/Tuner Knob Availability Navigation System: All Technical Service Bulletins Navigation Radio - Volume/Tuner Knob Availability INFORMATION Bulletin No.: 08-08-44-025A Date: September 11, 2008 Subject: Information On Navigation Radio Tuner And Volume Knobs Now Available For Service Replacements Models: 2007-2009 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Sierra, Yukon Models 2008-2009 HUMMER H2 Models with Navigation Radio (RPOs UVB or U3U) Supercede: This bulletin is being revised to add the 2009 model year. Please discard Corporate Bulletin Number 08-08-44-025 (Section 08 - Body and Accessories). The purpose of this bulletin is to announce that the Navigation Radio tuner and volume knobs are now available for service replacements. Previously, if either of these knobs was worn or broken, the entire radio assembly had to be replaced. The same part number is to be used for either knob. They are identical. Parts Information Disclaimer Page 17328 X313 Inline Harness Connector End Views X313 Sunroof Harness (CF5) or Overhead Console Harness (TRW/5X7/5Y0) to Right A-Pillar Harness (CF5/TRW/5X7/5Y0) X318 Inline Harness Connector End Views X318 Headliner Harness to CHMSL Harness Page 10218 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 11914 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Locations Air Flow Meter/Sensor: Locations Engine Controls Component Views Pedal Assemblies (JF4) Front of Engine Compartment 1 - Battery Current Sensor 2 - Mega Fuse 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Fuse Block Underhood 5 - Engine Control Module (ECM) 6 - A/C Refrigerant Pressure Sensor (C67/CJ2) 7 Mass Airflow (MAF)/Intake Air Temperature (IAT) Sensor 8 - Battery - Right Right Side of Engine Page 10036 Important The new canister vent valve will be installed in a new location, outside of the frame. 7. Position and secure the new valve assembly to the frame bracket on the outside of the frame using the existing hole and mounting bolt. Tighten Tighten the bracket mounting bolt to 12 Nm (106 lb in). 8. Connect the vent valve pipe to the EVAP canister. 9. Install the two vent valve pipe clips into the existing underbody holes. 10. Connect the EVAP canister vent valve electrical connector, if equipped. 11. Attach bulk 5/8" heater hose to the vent valve port and secure using a clamp. Run a length as needed along the frame rail routing to the area above the transmission. 12. Cut the hose to determined length and install the supplied filter box. Secure using a clamp. 13. Remove the transmission support and lower the transmission assembly as necessary to allow for access to the new filter box location. 14. Secure the filter box to the transmission vent hose just forward of the hose tee-section using a tie strap. DO NOT pinch or restrict the transmission vent hose. The filter box opening should be pointing downward. 15. Raise the transmission and reinstall the transmission support. 16. Tie strap the hose as needed along the frame rail in order to keep the hose away from pinch-points and heat sources. 17. Lower the vehicle. 2004-2007 Model Year (Use Service Kit P/N 19152349) 1. Raise the vehicle. Suitably support the vehicle. 2. Disconnect the EVAP canister vent valve electrical connector. 3. Disconnect the canister pipe from the vent valve. 4. Push in the retainer and remove the existing canister vent valve from the fuel tank clip or mounting bracket. Discard the old valve. 5. Cut back the existing canister pipe approximately 51 mm (2 in) to remove the quick connect end. Crew Cab Short Box Shown Below, Other Configurations Similar Diagram Information and Instructions Information Bus: Diagram Information and Instructions Electrical Symbols Electrical Symbols Page 5771 Page 21167 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 23128 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 8343 Information Bus: Connector Views Data Communication Connector End Views Data Communication Connector End Views Auxiliary Body Control Module (XBCM) X1 (Export) Auxiliary Body Control Module (XBCM) X2 (Export) Page 10775 Vehicle Zoning Strategy Truck Zoning Page 12867 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Repairing Connector Terminals Repairing Connector Terminals Tools Required J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. Page 8439 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9669 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Stop Lamp Switch Brake Light Switch: Diagrams Stop Lamp Switch Lighting Systems Connector End Views Stop Lamp Switch Page 11194 4. Disconnect the connector from the component. 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. Page 19957 Method 1 Method 2 Page 24670 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 23239 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring. 7. Remove the J 45722. 8. Remove the fuel tank module lock ring. Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints. 9. Slowly raise the module until the fuel level sensor float arm is just visible. Important: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm. 10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank. 11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container. Important: DO NOT reuse the old fuel tank module O-ring seal. 12. Remove and discard the fuel tank module O-ring seal. Important: * Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not Page 5922 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 12147 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Tools Required J-38125 Terminal Repair Kit Notice: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Tools Required J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors Page 7788 Checking Aftermarket Accessories Checking Aftermarket Accessories Do not connect aftermarket accessories into the following circuits: Caution: Refer to SIR Caution. * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. Notice: Refer to OBD II Symbol Description Notice. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker Page 3414 Transmission Speed Sensor: Service and Repair 6L50/6L80/6L90 - Automatic Transmission Input and Output Speed Sensor Replacement Page 23152 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 15025 17. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link. Ball Check Valves 18. Remove the 7 valve body checkballs. Important: Some models do not have an outer spring. Note spring usage during removal. 19. Remove the accumulator cover bolts (58, 59). 20. Remove the 1-2 accumulator cover and pin assembly (57). Page 5916 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 9623 cover. 4. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 14346 Page 12215 Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock until the lever is at the end of its travel. 2. Disconnect the connector from the component. 3. Pull the rubber boot that covers the wires back to expose the end of the connector dress cover. 4. Place the connector locking lever in the center of the connector. 5. Locate the 2 dress cover locking tabs that are on the wire end of the connector. Insert a small flat-bladed tool between the cover and connector body and pry up. 6. Locate the 2 dress cover locking tabs located on the opposite side of the connector. Insert a small flat-bladed tool between the cover at the connector end and pry up. 7. Remove the dress cover. 8. Cut the tie wrap on the wire bundle. Page 11000 Air Flow Meter/Sensor: Connector Views Engine Controls Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor Page 15921 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 13761 Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for a Short to Voltage Testing for a Short to Voltage Notice: Refer to Test Probe Notice. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Testing for Continuity Testing for Continuity Notice: Refer to Test Probe Notice. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the ohm position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Important: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. Page 24665 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing for Electrical Intermittents Testing for Electrical Intermittents Tools Required J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground * Testing for Continuity * Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Important: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Important: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. See: Testing and Inspection/Component Tests and General Diagnostics 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Tools Required * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring Page 15225 4. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Important: Position the piston in the bore so that it is straight and level. 5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove. Body - Squeak/Itching Noise in Upper Door Area Rear Door Weatherstrip: All Technical Service Bulletins Body - Squeak/Itching Noise in Upper Door Area TECHNICAL Bulletin No.: 06-08-64-035G Date: June 01, 2010 Subject: Squeak/Itching Noise in Upper Door Area (Replace Weatherstrip Assembly) Models: 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2010 GMC Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL Supercede: This bulletin is being revised to update parts description information. Please discard Corporate Bulletin Number 06-08-64-035F (Section 08 - Body and Accessories). Condition Some customers may comment on a squeaking or itching noise in the upper door area when driving. Cause This condition may be caused by the roof drip weatherstrip to door frame contact. This could occur at any or all of the doors. Correction Replace the weatherstrip assembly. Refer to Door Opening Weatherstrip Replacement in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the appropriate labor operation from the Labor Time Guide. Disclaimer Page 16466 X214 Inline Harness Connector End Views X214 Brake Clutch Harness to Fuse Block Jumper Harness (9L4) Page 10735 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 7301 4. Remove the CKP sensor bolt and sensor. Installation Procedure Important: When installing the CKP sensor, make sure the sensor is fully seated before tightening the bolt. A poorly seated CKP sensor may perform erratically and may set false diagnostic trouble codes (DTCs). Important: Do not reuse the original O-ring seal. 1. If reinstalling the old CKP sensor, install a NEW O-ring seal onto the sensor. 2. Lubricate the O-ring seal with clean engine oil. Notice: Refer to Fastener Notice. 3. Install the CKP sensor and bolt. Tighten the bolt to 10 N.m (89 lb in). Page 7975 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 7257 8. Use the J 38125-213 or the J 38125-560 (GM P/N 15314260) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 9. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Molex Connectors Molex Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 23388 Important: Always replace the fuel tank module seal when installing the fuel tank module. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove. Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction. 6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring. 7. Remove the J 45722 (1) from the fuel tank module lock ring. 8. Position the fuel and EVAP pipes to the module. 9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. 10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. 11. Install the fuel tank. Page 9466 Connector Position Assurance Locks Connector Position Assurance Locks The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals, of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, * Connector Position Assurance Locks * Terminal Position Assurance Locks * Bosch Connectors (BSK) Bosch Connectors (0.64) Bosch Connectors (2.8 JPT) Bosch Connectors (ECM) * Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro.64) Delphi Connectors (12-Way) * Tyco/AMP Connectors (CM 42-Way) Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (0.25 Cap) Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (Door Module) * Yazaki Connectors (2-Way) Yazaki Connectors (16-Way) * Repairing Connector Terminals Connector Anatomy 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Page 12079 View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. 6. Release the rear lower half of the wiredress cover. Page 10823 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 1140 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 9512 2. Insert the J 38125-11A (GM P/N 12094430) tool into the cavity on the lower right hand face of the connector until the terminal release tang access panel slides over. 3. Ensure that the terminal release tang access panel is in the correct location to access the terminals. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-11A (GM P/N 12094430) into the terminal release tang access slot located behind the access panel of the connector and press down on the terminal while carefully pulling the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Page 5142 The first connector design of the Micro-Pack 100W (1) has a white connector interface that holds the terminals. The second design of the Micro-Pack 100W (2) has a gray interface to hold the terminals. Also, the first design has terminal cavities that are further apart (3 mm centerline) and offset from the other row of terminal cavities in the connector. The second design has terminals cavities that are closer together (2.54 mm centerline) and aligned vertically. One other way to identify the second design is the thin strip of material that runs along the outside of the cavities. Important: There are 2 styles of Micro-Pack 100W terminals which are very similar. Ensure that you have the correct terminal before crimping the new terminal to the wire. The first design connector uses the longer terminal (1) that has a raised area in front of the recess in the terminal. The second design connector uses the shorter terminal without the raised area. Follow the steps below in order to remove terminals from Micro-Pack 100W connectors. Some Micro-Pack 100W connector disassembly procedures will vary. Use this procedure as a guide. 1. Disconnect the connector from the component. Page 13670 Important: DO NOT hold the transmission end (1) during this operation, this will result in a mis-adjusted cable. 7. Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system. 8. Pull the white cover (5) on the shifter end (1) back. 9. Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3). 10. Release the white cover (1). 11. Verify the white cover (1) conceals the natural colored lock (2). 12. If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below. 13. Lower the vehicle. 14. Test the transmission for proper shift operation. 15. If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below. Cable Re-Adjustment Page 6731 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 15915 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Service and Repair Seat Memory Switch: Service and Repair Driver Seat Adjuster Memory Switch Replacement (Crew Cab) Page 7219 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 2009 lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If re-installing the old sensor, coat the threads with sealant GM P/N 12346004 (Canadian P/N 10953480), or equivalent. Notice: Refer to Fastener Notice. 2. Install the ECT sensor to the cylinder head. Tighten the sensor to 20 N.m (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill). Page 14232 6. Install the pinion into the pinion gear bearing retainer. 7. Install the outer pinion bearing onto the pinion. 8. Install a new pinion oil seal using the J 44414. 9. Apply sealant, GM P/N 12346004 (Canadian P/N 10953480) or equivalent, to the splines of the pinion yoke. 10. Install the pinion yoke. Align the marks made during removal. Notice: Do not hammer the pinion flange/yoke onto the pinion shaft. Pinion components may be damaged if the pinion flange/yoke is hammered onto the pinion shaft. 11. Seat the pinion yoke onto the pinion shaft by tapping it with a soft-faced hammer until a few pinion shaft threads show through the yoke. 12. Install the washer and a new pinion nut. 13. Install the J 8614-01 onto the pinion yoke as shown. Notice: Refer to Fastener Notice. Important: If the rotating torque is exceeded, the pinion will have to be removed and a new collapsible spacer installed. 14. Tighten the pinion nut while holding the J 8614-01. Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Page 18641 Low Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Low Pressure Switch Replacement (Non-HP2) Removal Procedure 1. Disconnect the electrical connector from the A/C low pressure switch. 2. Remove the A/C low pressure switch from the accumulator. 3. Remove the O-ring and discard. Installation Procedure 1. Install the new O-ring seal to the switch. Notice: Refer to Fastener Notice. 2. Install the A/C low pressure switch to the accumulator. Tighten the switch to 6 N.m (53 lb in). 3. Connect the electrical connector to the A/C low pressure switch. 4. Leak test the fittings of the components using the J 39400-A. Page 16686 Page 287 Memory Seat Module X5 (AN3) Page 6728 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 2860 Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Interior - Front Door Panel Rattles Loose Front Door Panel: Customer Interest Interior - Front Door Panel Rattles Loose TECHNICAL Bulletin No.: 07-08-110-010A Date: April 14, 2008 Subject: EI07321 - Inner Door Panel Rattle Noise/Loose (Inspect/Replace Clips) Models: 2007-2008 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2008 GMC Sierra, Yukon, Yukon Denali, Yukon XL Supercede: This bulletin is being revised to end the need for technician feedback and to provide corrective action. Please discard Corporate Bulletin Number 07-08-110-010 (Section 08 - Body and Accessories). Condition Some customers may comment on any of the following conditions: ^ a rattling noise coming from inside the door or the door panel ^ a poor fit of the inner door panel ^ a loose door panel Cause Engineering has determined that some of the door panel clips may have been damaged during assembly. Correction DO NOT REPLACE THE DOOR TRIM PANEL. Remove the interior door panel and inspect the clips for damage. Replace the clips if necessary and reinstall the door panel. If the clips are not missing or damaged, it is possible to correct the customers concern by reinstalling the door panel, ensuring the clips are fully seated. In the event that the customers concern is NOT related to the clips or corrected by reinstalling the door panel submit a Field Product Report (refer to bulletin # 02-00-89-002F). This information will provide engineering with the cause and correction of the customers complaint. Parts Information Important: There are a total of seven (7) white retainers and four (4) black retainers used per door trim panel. The retainers are shipped one per package. The technician will need to determine how many of each retainer is necessary to complete the repair. Warranty Information Page 12734 View of the male half of the connector with female terminals. 4. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Flat Wire Repairs Flat Wire Repairs Notice: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Tools Required J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool (GM P/N 12085115) * J 38125-5 Ultra Torch Special Tool (GM P/N 12085116) The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. Page 2610 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Locations Coolant Level Sensor: Locations Cooling System Component Views Left Front of Engine Compartment (Diesel) 1 - Engine 2 - Front Fascia 3 - A/C Low Pressure Switch (C67/CJ2) 4 - Surge Tank 5 - Engine Coolant Level Switch Page 14864 1. Prior to installation the terminal must be aligned so the (1) coding lugs align with the (2) coding grooves on the connector. 2. Once the terminal is aligned, slide the terminal into the cavity until the retainer has engaged in the cavity of the connector. 3. Slide the TPA in the connector body and seat it using a small flat bladed tool. The TPA is seated when it is flush with the contact housing. 4. Secure the wires to the connector body using a tie wrap and replace the dress cover and grommet. Bosch Connectors (2.8 JPT) Bosch Connectors (2.8 JPT) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Pull out the slider on the connector position assurance (CPA) until it is at the end of its travel. 2. Disconnect the connector from the component. 3. Remove the wire dress cover, if necessary. 4. Push the wire side of the terminal that is being removed toward the connector and hold it in position. 5. Insert the J 38125-557 (GM P/N 12122378) into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Page 13590 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 23063 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 15176 Page 9942 Transmission Position Switch/Sensor: Diagrams Automatic Transmission Related Connector End Views Transmission Range Switch, Wiring Harness Side Page 11902 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 4917 Depress the locks that are located on both sides of the wiredress cover and pull the lever over and past the locks. View of the connector when released from the component. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the front of the connector. Using a small flat-blade tool push down on one of the locking tabs and pull the Page 2697 J-38125 Terminal Repair Kit 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original (except fusible link). * The wire insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. * Ensure that the wires extend beyond the clip in each direction. * Ensure that no insulation is caught under the clip. 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. Page 15033 Notice: Refer to Fastener Notice. 1. Place the new TFP manifold assembly (2) in position and install one bolt (1) in a recessed location to hold in position. Start the remaining five bolts (1) in recessed locations and tighten the bolts by hand. Torque the bolts to 12 N.m (108 lb in). 2. Connect the internal wiring harness connector to the TFP switch. 3. Install the oil pan and transmission internal oil filter. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 4. Perform the FastLearn procedure. Refer to FastLearn Procedure. Page 6547 Knock Sensor: Connector Views Engine Controls Connector End Views Knock Sensor (KS) - 1 Knock Sensor (KS) - 2 Page 20516 Body Control Module: Diagrams Data Communication Connector End Views Body Control Module (BCM) X1 Page 16176 3. Slide the lever lock forward while pressing down on the lever lock release tab. View showing depressing of the lever lock release tab. Page 17546 Install the lower B-pillar cover. Parts Information Warranty Information The labor operation associated with this bulletin is written for inspection of the B-pillar wiring harness and, if necessary, repair. Page 17820 Page 2611 producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Notice: Refer to Test Probe Notice. The following procedure determines the frequency of a signal. Important: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Notice: Refer to Test Probe Notice. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to one end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Measuring Voltage Drop Measuring Voltage Drop Notice: Refer to Test Probe Notice. The following procedure determines the difference in voltage potential between 2 points. Page 15394 Page 14730 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 632 Page 12820 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 3820 equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure). 10. With the ignition OFF, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 11. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 12. If the brake pedal feels spongy, repeat the automated bleeding procedure. If the brake pedal still feels spongy after repeating the automated bleeding procedure inspect the brake system for external leaks. Refer to Brake System External Leak Inspection. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection 13. Turn the ignition key ON, with the engine OFF; check to see if the brake system warning lamp remains illuminated. 14. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes 15. Drive the vehicle to exceed 13 km/h (8 mph) to allow ABS initialization to occur. Observe brake pedal feel. 16. If the brake pedal feels spongy, repeat the automated bleeding procedure until a firm brake pedal is obtained. 4L60-E/4L65-E/4L70-E - Automatic Transmission Transmission Position Switch/Sensor: Locations 4L60-E/4L65-E/4L70-E - Automatic Transmission Automatic Transmission Electronic Component Views Park Neutral Position (PNP) Switch Park Neutral Position (PNP) Switch 1 - Automatic Transmission 4L60-E/4L65-E/4L70-E 2 - Park/Neutral Position (PNP) Switch Page 11156 4. The terminal positive assurance (TPA) is located in the front of the connector. 5. Use a small flat-blade tool to remove TPA from the connector. Page 7804 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 6139 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement (4.3L) Removal Procedure 1. Remove the negative battery cable. 2. Mark the location of the battery current sensor on the battery cable with tape for reference during installation. 3. Remove the tape securing the battery current sensor to the negative battery cable. 4. Mark the location of the negative battery cable clips (1) and remove the clips from the cable. 5. Squeeze the negative battery cable branches together. Important: Note the orientation of the battery current sensor prior to removal. 6. Slide the battery current sensor (2) off of the negative battery cable. Installation Procedure Restraints - Passenger Presence System Information Seat Occupant Sensor: All Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 7819 View of the connector when released from the component. View of another type of Micro 64 connector. Page 9334 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 1712 Turn Signal/Malfunction Switch X3 Page 8958 3. Use a small flat-bladed tool to gently pry off the dress cover by inserting the tool under the cover opposite the harness side and prying up. 4. Remove the cover. 5. Using a small flat-bladed tool, push on the side of the nose piece retainer while pushing the nose piece forward with your thumb. This will release the terminal position assurance (TPA). 6. Insert the J 38125-12A (GM P/N 12094429) into the corresponding terminal release cavity. The release cavities are the 2 center rows of cavities on one half of the connector. Page 24283 Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement (Crew Cab) Rear Side Door Window Switch Replacement (Crew Cab) Page 21177 Front Fender Liner: Service and Repair Front Wheelhouse Liner Replacement - Right Side Front Wheelhouse Liner Replacement - Right Side (Chevrolet) Procedures Seat Belt Tensioner: Procedures Pretensioner Handling and Scrapping Caution: When carrying an undeployed inflatable restraint seat belt pretensioner: * Do not carry the seat belt pretensioner by the wires or connector. * Carry the seat belt pretensioner by the piston tube, keeping hands and fingers away from the cable. * Make sure the open end of the seat belt pretensioner piston tube points away from you and other people. * Do not cover the seat belt pretensioner piston tube opening with your hand. Failure to observe these guidelines may result in personal injury. Scrapping Procedure During the course of a vehicles useful life, certain situations may arise which will require the disposal of a live and undeployed seat belt pretensioner. Do not dispose of a live and undeployed seat belt pretensioner through normal disposal channels until the seat belt pretensioner has been deployed. The following information covers the proper procedures for disposing of a live and undeployed seat belt pretensioner. Do not deploy the seat belt pretensioner in the following situations: * After replacement of a seat belt pretensioner under warranty. The seat belt pretensioner may need to be returned undeployed to the manufacturer. * If the vehicle is the subject of a Product Liability report, GM1241, related to the SIR system or the seat belt system. If the vehicle is subject to the Product Liability report, do not alter the SIR or seat belt system in any manner. * If the vehicle is involved in a campaign affecting the seat belt pretensioners. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Deployment Procedures The seat belt pretensioner can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Deployment Outside Vehicle for Seat Belt Pretensioners Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: * Using the SIR diagnostics, it is determined that the seat belt pretensioner is malfunctioning. * The seat belt pretensioner pigtail, if equipped, is damaged. * The seat belt pretensioner connector is damaged. * The seat belt pretensioner connector terminals are damaged. Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required retention period. Caution: In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflatable restraint seat belt pretensioner as normal shop waste. Undeployed seat belt pretensioners contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed seat belt pretensioner. Failure to observe the following disposal methods may be a violation of federal, state, or local laws. Tools Required * J 39401-B SIR Deployment Fixture * J 38826 SIR Deployment Harness * An appropriate pigtail adaptor Page 1792 or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. See: Testing and Inspection/Component Tests and General Diagnostics * Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation. See: Testing and Inspection/Component Tests and General Diagnostics Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Temperature Sensitivity Page 5473 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. See: Testing and Inspection/Component Tests and General Diagnostics SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Tools Required J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Page 8750 Body Control Module (BCM) X3 Page 6806 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. * Cut as little wire off the harness as possible. * Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches, and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. * The wire must be of equal or greater size than the original. * The wires insulation must have the same or higher temperature rating (4). - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. * Select the correct size opening in the wire stripper or work down from the largest size. * Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table. 6. Place the duraseal splice sleeve in the J-38125-8 (GM P/N 12085115) crimp tool nest so that the crimp falls at point 1 on the splice. 7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest. 8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 9. Close the handles of the J-38125-8 (GM P/N 12085115), until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 10. Shrink the insulation around the splice. * Using the heat torch, apply heat to the crimped area of the barrel. * Gradually move the heat barrel to the open end of the tubing. Page 6877 4. Insert the J 38125-561 tool into the 2 cavities on each side of the terminal at the front of the connector and push until you feel the tool disengage the terminal retainers. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. Carefully pull the terminal out of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is difficult to remove, repeat the entire procedure. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Bosch Connectors (ECM) Bosch Connectors (ECM) Tools Required J-38125Terminal Repair Kit Removal Procedure 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. Page 7388 5. Once the nose piece retainers are relaxed, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J-38125-552 (15313892) to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 22998 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. Important: The TPA is fragile and may break if not done carefully. View of the male half of the connector with female terminals. Page 3610 Step 8 - Step 13 Page 14230 19. Remove the pinion. 20. Remove the collapsible spacer. 21. Remove the inner pinion bearing from the pinion using the J 22912-B and a hydraulic press. 22. Remove the outer pinion bearing cup using a hammer and a brass drift in the slots provided. Move the drift back and forth between one side of the cup and the other in order to work the cups out of the retainer evenly. Page 6346 6. Use the J 38125-12A (GM P/N 12094429) tool to release the terminals by pressing on the tang. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Tyco/AMP Connectors (Sensor) Tyco/AMP Connectors (Sensor) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 13335 following: Important Typical Freeze Frame operating conditions: ISS >500 RPM, OSS =0 RPM, Vehicle Speed >0 MPH - Replace the Internal Mode Switch (IMS) if the Vehicle Build Date is prior to March 31, 2007. If not, continue with this bulletin. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 4. If the DTC does not reset and original freeze frame data reports an IMS A/B/C/P code of LLLH, LLHL, LHLL or PNP Switch is P/N in all gears, failure is a short to ground condition and is most likely in the Control Solenoid (with body and TCM) Valve Assembly (TEHCM), complete the following: - Obtain the following data and contact the PQC as the Control Solenoid (with body and TCM) Valve Assembly (TEHCM) is currently on restriction. The PQC will engage engineering for additional diagnostic support. - Capture or record freeze frame or fail records if a DTC is set. - Document the diagnostics completed leading to the decision to replace the control solenoid valve and transmission control module. Important There is no calibration update for vehicles equipped with a 6L90 RPO MYD transmission or 2008 model year vehicles. These calibrations were updated before production began. - Update the TCM calibration file to the latest released on TIS2WEB. - After completing the above steps, test drive the vehicle, moving the shifter through all detent positions. If no issues are found, ensure all DTC codes are cleared from history and return the vehicle to the customer. 5. If the DTC does not reset and the original freeze frame data reports an IMS A/B/C/P code of LLLH and the vehicle is a 2009 CTS, STS or SRX, the condition is most likely caused by an incorrectly adjusted shift linkage. Important Typical Freeze Frame operating conditions: ISS and OSS both =0 RPM or ISS and OSS both >0 RPM and/or vehicle is in some drive gear (transmission gear ratio matches one of the forward gear ratios). - Using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. - Perform the Shift Control Linkage Adjustment as detailed in SI. - After adjustment, using a Tech 2(R), pull backward firmly/hard on the shifter to verify that the IMS A/B/C/P code remains at the correct HLLH reading. If it toggles to LLLH or LLLL, the linkage is not adjusted properly. Repeat the adjustment. - If no shifter adjustment issues are found, return to Step 4. ACTIVE DTC/FAULT ACTIVE If the fault is still active per Step 2 above, or after a test drive, continue with component tests defined below: 1. Ensure proper system performance: - Inspect the shift cable for incorrect routing, kinks, severe bends and/or a damaged or twisted rubber boot at the transmission end of the cable. - Check and ensure proper cable adjustment. - Remove the transmission oil pan and repeat the shift lever movement, ensuring that the detent spring roller moves to the bottom of the valley on the detent plate for each shift lever position. Inspect the detent spring roller and ensure it is centered on the detent plate. The spring arms should not be rubbing on either the IMS arm or detent plate. 2. Disconnect the IMS connector at the Control Solenoid (w/body and TCM) Valve Assembly (TEHCM). With the Tech 2(R) connected and the ignition ON and engine OFF, the Tech 2(R) should report all IMS states A/B/C/P as high (H) and the PNP Switch should display "In Gear". - If any of the A/B/C/P circuits displays low (L), the TEHCM is faulty and should be replaced. If the Vehicle Build Date is prior to March 31, 2007, also replace the IMS. - If the PNP Switch Circuit (Tech 2(R) Engine data) displays "Park/Neutral", a short exists in the TEHCM or the wiring connecting it to the ECM. Disconnect the transmission pass-through connector. Check for continuity between the pass-through P/N Signal pin 3 (refer to Page 15270 7. Using the J 39544-KIT, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation. 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement. See: Brake Rotor Assembled Lateral Runout Measurement 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction. See: Brake Rotor Assembled Lateral Runout Correction 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. Page 9061 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 24151 Page 8421 * Yazaki has a wedge or arrow shape, similar to that shown. Delphi Connectors (Micro .64) Delphi Connectors (Micro.64) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from Micro.64 connectors. 1. Locate the lever lock on the wire dress cover. While depressing the lock, pull the lever over and past the lock. The lever lock may be located on the top or sides of the wire dress cover. Campaign - Possible Air-Bag Deployment/Servce Light ON Technical Service Bulletin # 09184A Date: 091026 Campaign - Possible Air-Bag Deployment/Servce Light ON CUSTOMER SATISFACTION Bulletin No.: 09184A Date: October 26, 2009 Subject: 09184A - Material Over Sensing and Diagnostic Module Retaining Moisture Models: 2007-2009 Chevrolet Silverado 2007-2009 GMC Sierra Currently or Previously Registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, , West Virginia, Wisconsin Supercede: This bulletin has been revised to include an inspection procedure and a new labor code. Vehicles with vinyl flooring and no cutout flap require no repair. All technicians are to review the new inspection procedure immediately. Please discard all copies of bulletin 09184, issued October 2009. Condition Certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin may have a condition where an electronic component located beneath the driver's seat may corrode due to a significant quantity of snow and/or water containing road salt or other contaminants entering the vehicle and saturating the acoustical padding beneath the carpet. The vehicle's electronic sensing and diagnostic module (SDM) is located underneath this acoustical padding. If sufficient moisture collects and is retained in the padding, it may cause excessive corrosion under the module; compromising the module seal and allowing water intrusion and system malfunction. This may result in illumination of the Airbag Readiness light, along with a "Service Airbag" message on the Driver Information Center, and in rare cases, deployment of the seat belt pretensioner and/or airbags. Correction Dealers are to remove the acoustical pad above the SDM. Vehicles Involved Involved are certain 2007-2009 model year Chevrolet Silverado and GMC Sierra vehicles currently or previously registered in Connecticut, Delaware, District of Columbia, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, and Wisconsin, and built within these VIN breakpoints: Page 3799 3. Install the drain plug. Tighten the plug to 25 N.m (18 lb ft). 4. Lower the vehicle. 5. Fill the engine with the proper capacity and quality of engine oil. Refer to Approximate Fluid Capacities. 6. Operate the engine, check for leaks, and oil pressure. Page 11711 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Sumitomo Connectors Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 8888 Page 7883 Page 3157 The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Important: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 2799 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. Page 3887 Fuse: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. Arrows and Symbols 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed With Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Basic Knowledge Required General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service data. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Customer Concern Verification Sheets Customer Concern Verification Sheets The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time. The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally. Decimal and Metric Equivalents Decimal and Metric Equivalents Exhaust System - Rattle/Thud Noise On Left Turns/Bumps Exhaust Pipe/Muffler Hanger: Customer Interest Exhaust System - Rattle/Thud Noise On Left Turns/Bumps TECHNICAL Bulletin No.: 09-06-05-004 Date: May 20, 2009 Subject: Rattle or Thud Type Noise During Left Turns or While Driving Over Bumps (Perform Repair as Outlined) Models: 2007-2009 Chevrolet Silverado 1/2 Ton 1500 Series (Including Hybrid) 2007-2009 GMC Sierra 1/2 Ton 1500 Series (Including Hybrid) Condition Some customers may comment on a rattle or thud type noise during left turns or while driving over bumps. Cause This condition may be caused by contact between the front exhaust hanger and the frame hanger. Correction Perform the repair below to eliminate the contact between the front exhaust hanger and the frame hanger. 1. Raise and support the vehicle. 2. Measure the clearance (1) between the front exhaust hanger and the frame hanger. There should be at least 8 mm (0.315 in) clearance. Witness marks may also be visible. - If the clearance is less than specified, proceed to step 3. - If the clearance is within specification, diagnose and repair using the information found in SI. 3. Grind or file the front exhaust hanger head until the remaining material measures 4 mm (0.157 in). 4. Lower the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Page 10125 pressure should stabilize and remain constant. 1. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027). 2. Install the J 37287 between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gage. 5. Close the valve on the J 37287. 6. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure drops, locate and replace the leaking fuel injector. 7. If the fuel system test normal, replace the fuel pump. 2. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump. 3. Remove the J 37287 and CH-48027. 4. Operate the vehicle within the conditions of the customers concern while monitoring the fuel trim and O2 parameters with a scan tool. The scan tool parameters should not indicate a lean condition. ‹› If the scan tool parameters indicate a lean condition, test for a restricted fuel feed pipe, restricted fuel filter, or poor connections at the harness connectors and ground circuits of the fuel pump. If all test normal, replace the fuel pump. 5. If the fuel system components test normal, refer to Symptoms - Computers and Control Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls Repair Instructions Perform the Diagnostic Repair Verification after completing the diagnostic procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures * Fuel Injector Replacement * Fuel Sender Assembly Replacement (Regular Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Extended Cab w/26 Gal Tank) Fuel Sender Assembly Replacement (Regular Cab w/34 Gal Tank) Page 12511 Shift Solenoid: Specifications 6L50/6L80/6L90 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Shift Solenoid Valve State and Gear Ratio Page 17673 Important: Do not reuse the old idler arm nut. 4. Install the new idler arm nut (3) to the idler arm (1). Tighten the nut to 62 N.m (46 lb ft). 5. Install the engine shield, if equipped. 6. Adjust the front toe. Page 23608 Important: The TPA cannot be removed from the connector while there are terminals present in the connector body. View of the TPA when removed from the connector body. 4. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. A/C - Defaults To Full Hot/Full Cold/DTC's Set Control Module HVAC: All Technical Service Bulletins A/C - Defaults To Full Hot/Full Cold/DTC's Set TECHNICAL Bulletin No.: 08-01-39-009B Date: September 24, 2010 Subject: HVAC Automatic Climate Control Defaults to Full Cold or Full Hot Despite Controls Being Set to Other Parameters, DTCs B0228, B0413, B0423, B0433, B3779 or B3782 Set (Reprogram HVAC Control Module) Models: 2008-2009 Buick Enclave 2007-2008 Cadillac Escalade Models 2007-2008 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2007-2009 GMC Acadia, Sierra, Yukon Models 2008 HUMMER H2 Models 2007-2009 Saturn OUTLOOK with Automatic Climate Control System (RPO CJ2) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 08-01-39-009A (Section 01 - HVAC). Condition Some customers may comment that the Heating, Ventilation and Air Conditioning (HVAC) automatic climate control system defaults to full hot and/or full cold, despite the HVAC controls being set to other parameters. This condition may not exist during the next ignition cycle and the system may operate normally. Technicians may find DTCs B0228, B0413, B0423, B0433, B3779 or B3782 set as Current or in History. Cause This condition may be caused by a software anomaly. Correction Important If the vehicle is a 2007-2009 GMC Acadia or Saturn OUTLOOK with an additional customer concern of an inaccurate ambient temperature display, then it may be necessary to reprogram the HVAC control module AND relocate the ambient air temperature (AAT) sensor. Refer to Corporate Bulletin Number 08-01-39-008A - HVAC Ambient Temperature Sensor Display In Instrument Panel Cluster (IPC) Inaccurate Or Too High for more information. Note The first step applies to the following vehicles: Avalanche, Escalade, Suburban, Tahoe, Yukon. 1. Inspect for an open HVAC-IGN Fuse in the underhood fuse block. ‹› If the fuse is open, repair the short to ground. 2. A revised calibration has been released to address this condition. Reprogram the HVAC control module using the Service Programming System (SPS) with the latest calibration available on TIS2WEB. Refer to the HVAC Control Module Programming and Setup procedure in SI. 3. When using a multiple diagnostic interface (MDI) for reprogramming, ensure that it is updated with the latest software version. 4. When using a Tech 2(R) for reprogramming, ensure that it is updated with the latest software version. 5. During programming, the battery voltage must be maintained within the proper range of 12-15 Volts. Only use the approved Midtronics(R) PSC 550 Battery Maintainer (SPS Programming Support Tool EL-49642) or equivalent during programming. 6. After reprogramming clear all DTCs. Operate the vehicle within the Conditions for Running the DTC and verify that DTCs B0228, B0413, B0423, B0433, B3779 or B3782 do not reset as Current. ‹› If DTCs B0228, B0413, B0423, B0433, B3779, or B3782 are set as Current, refer to the DTC diagnostic procedures in SI. Page 18140 Wheels: Description and Operation Steel Wheel Repair Description Steel Wheel Repair Description Notice: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. Notice: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Page 1785 - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (2). If not broken (1), also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link Important: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Page 22438 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 1329 1 - Tail/Stop and Turn Signal Lamp - Upper Left 2 - Tail/Stop and Turn Signal Lamp - Upper Right 3 - Tail/Stop and Turn Signal Lamp - Lower Right 4 - Marker Lamp - Right Rear 5 - Backup Lamp Right Rear 6 - Object Sensor - Right Rear Corner (UD7) 7 - License Lamp - Right 8 - Object Sensor - Right Rear Middle (UD7) 9 - Marker Lamp - Tailgate (R05) 10 - Object Sensor - Left Rear Middle (UD7) 11 - License Lamp - Left 12 - Object Sensor - Left Rear Corner (UD7) 13 - Backup Lamp - Left Rear 14 - Marker Lamp - Left Rear 15 - Tail/Stop and Turn Signal Lamp - Lower Left Page 8529 Page 7212 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 6248 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended. Important: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the mylar tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. US English/Metric Conversion US English/Metric Conversion Page 355 Electronic Brake Control Module: Diagrams Electronic Brake Control Module (JF3/JF7) Electronic Brake Control Module (JF3/JF7) Page 8620 Important: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Important: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Important: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. See: Testing and Inspection/Component Tests and General Diagnostics If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Page 16277 Junction Block - Left I/P X10 Junction Block - Left I/P X11 Page 23994 Hazard Flasher Relay: Diagrams Wrecker Relay X1 (5X7) Power and Grounding Connector End Views Wrecker Relay X1 (5X7) Page 5461 Important: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 5. Release the TPA by inserting a small flat-blade tool into the blue locking tabs on both ends of the connector. Gently slide the TPA up to the released position on both ends. 6. For the larger terminals insert the J 38125-13A (GM P/N 12031876-1) tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6657 5. While pushing the terminal forward, insert the J 38125-24 in the release cavity above the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (43-Way) Tyco/AMP Connectors (43-Way) Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Locate the lever lock on the wire dress cover. Slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. 4. Once the locks are unlocked, lift the dress cover off. Page 17923 Note Do Not attempt to drill out the jounce bumper while attached to the strut top mount assembly. The bumper must be removed from the top mount assembly. Note Do Not attempt to drill out the jounce bumper from the lower end toward the upper end, as this could affect characteristics of the jounce bumper. 10. Enlarge the Upper ID (1) from the top side of the jounce bumper to the following dimensions: - Diameter of enlarged ID: 16 mm - Depth of enlarged ID: 15 mm 11. Ensure that the ID of the jounce bumper is as smooth as possible and free of loose material. If necessary, an Exacto knife, or equivalent, can be used to carefully trim the edge and remove any loose material. The photo above shows a jounce bumper with the enlarged upper ID (1) as compared to the original ID (2). Note Ensure that the jounce bumper is fully seated to the top mount assembly. 12. Install the jounce bumper to the top mount assembly. Ensure that the jounce bumper is secure to the top mount. 13. Assemble the coil spring and top mount to each strut. Refer to Shock, Shock Component, and/or Spring Replacement in SI. 14. Install the LH and RH strut assemblies to the vehicle. Refer to Shock Absorber and Spring Assembly Replacement in SI. 15. Move the vehicle outdoors to allow it to return to ambient temperature. 16. Test drive the vehicle under the same conditions to verify the repair. Warranty Information For vehicles repaired under warranty, use the table. Page 22930 * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required. See: Testing and Inspection/Component Tests and General Diagnostics Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories. See: Testing and Inspection/Component Tests and General Diagnostics * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Important: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming. See: Testing and Inspection/Programming and Relearning Testing for Short to Ground Testing for Short to Ground Notice: Refer to Test Probe Notice. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the ohm position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. Page 4711 Important: Notice the direction of the rear oil seal. The new design seal is a reverse style as opposed to what has been used in the past. THIS SIDE OUT has been stamped into the seal as shown in the graphic. 5. Inspect the J 35621-B flange for imperfections that may damage the NEW seal. Minor imperfections may be removed with a fine grade emery cloth. Important: DO NOT allow oil or any other lubricants to contact the seal lip surface of the seal. 6. Remove the sleeve from the seal. 7. Apply 2 to 3 drops of clean engine oil to the outside diameter of the seal. 8. Install the seal onto the J 35621-B. 9. Install the J 35621-B onto the rear of the crankshaft and hand tighten the tool bolts until snug. Notice: Proper alignment of the crankshaft rear oil seal is critical. Install the crankshaft rear oil seal near to flush and square to the crankshaft rear oil seal housing. Failing to do so may cause the crankshaft rear oil seal or the crankshaft rear oil seal installation tool to fail. 10. Install the seal onto the crankshaft and into the housing: 1. Turn the J 35621-B wing nut clockwise until the seal is installed close to flush and square to the housing. Increased resistance will be felt when the seal has reached the bottom of the housing bore. 2. Turn the J 35621-B wing nut counterclockwise to release the J 35621-B from the seal. 11. Remove the J 35621-B. 12. Wipe off any excess engine oil with a clean rag. 13. Install the engine flywheel. Page 2529 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 17715 Power Brake Booster Inlet Hose Replacement Page 5912 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 6692 Tighten the sensor to 42 N.m (31 lb ft). 3. If vehicle is a 4WD perform the following steps otherwise proceed to step 7. 4. Install the HO2S pigtail electrical connector clip (9) to the fuel line bracket. 5. Connect the engine wiring harness electrical connector (7) to the HO2S pigtail electrical connector (8). 6. Connect the CPA retainer. 7. If vehicle is a 2WD perform the following steps, connect the HO2S pigtail electrical connector (7) to the engine wiring harness electrical connector (6). 8. Connect the CPA retainer. 9. Lower the vehicle. Locations Pressure Regulating Solenoid: Locations Automatic Transmission Electronic Component Views Electronic Components 36 - Vehicle Speed Sensor (VSS) - Model Dependent 66 - Torque Converter Clutch (TCC) Solenoid Valve 69 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 250 - Input Speed Sensor (ISS) Assembly - Model Dependent 367a - 1-2 Shift Solenoid (SS) Valve 367b - 2-3 Shift Solenoid (SS) Valve 377 - Pressure Control (PC) Solenoid Valve 394 - 3-2 Shift Solenoid (SS) Valve Assembly 396 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve Page 20953 For vehicles repaired under warranty, use the table. Disclaimer Interior - Proper Use of Floor Mats Carpet: All Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Page 2537 View of the release tool being used for the larger terminals. View of the release tool being used for the larger terminals. Page 2120 Page 12389 1. Place the new detent lever/IMS assembly (4) in position in the transmission case. Rotate the detent lever/IMS assembly to engage the park pawl apply assembly (2). Reinstall the manual shift shaft (5) through the manual shift shaft seal and through the detent lever/IMS assembly (4). Notice: Refer to Fastener Notice. 2. Push the manual shift shaft (5) into the final position in the transmission case. 3. Install the spherical pin (3) into the transmission case that retains the manual shift shaft. 4. Install the detent lever/IMS retaining bolt (1) using a T27 TORX(R) bit. Tighten the bolt (1) to 10 N.m (92 lb in). 5. Install the control valve assembly. Important: The FastLearn, adapt, procedure must be performed. This can be done in 1 step using a scan tool. If this procedure is not done, the TCM adaptive values will be at the settings that it learned for the old components and will be in slow adaptive mode. Under these conditions, it will take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission. 6. Perform the FastLearn procedure. Refer to FastLearn Procedure. HVAC - Automatic Air Door Actuator / Motor: Service and Repair HVAC - Automatic Air Temperature Actuator Replacement Air Temperature Actuator Replacement Air Temperature Actuator Replacement - Right Side Air Temperature Actuator Replacement - Right Side Page 21795 Page 5123 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (BSK) Bosch Connectors (BSK) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component. 2. Remove the wire dress cover, if necessary. 3. Push the wire side of the terminal that is being removed toward the connector and hold it in position. Page 533 Vehicle Zoning Strategy Truck Zoning Page 3016 7. Pressing the J 38125-12A (GM P/N 12094429) tool in the release cavity of the terminal you are removing, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Tyco/AMP Connectors (Door Module) Tyco/AMP Connectors (Door Module) Tools Required J-38125 Terminal Repair Kit Removal Procedure Side view of connector. View of top of connector. 1. Locate the assist lever and lock on the top of the connector. Page 6295 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 21062 7. Install the rear sliding window pulley covers (2) to the pulley (3), clip the tabs (1) in place. 8. Install the rear sliding window stops (1) in place and fully seated. 9. Cycle the rear sliding window to the fully closed position. 10. Install the lower garnish molding. 11. Inspect the rear sliding window for proper operation. 12. Clean the window. Page 21506 Page 11016 Vehicle Zoning Strategy Truck Zoning Page 5416 * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. Page 22975 5. The terminal positive assurance (TPA) is located in the front and rear of the connector. 6. Use a small flat-blade tool to remove the rear TPA from the connector. Important: The front TPA cannot be removed from the connector. Only move it to the release point. 7. Use a small flat-blade tool to move the front TPA to the release position. Page 24748 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Tools Required J-38125 Terminal Repair Kit Important: Use only duraseal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using duraseal splice sleeves. Page 2309 Manifold Pressure/Vacuum Sensor: Diagrams Engine Controls Connector End Views Manifold Absolute Pressure (MAP) Sensor Page 15430 Page 8110 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 15951 Auxiliary Power Outlet: Connector Views Power Outlet Connector End Views Auxiliary Power Outlet - Bin (D07) Auxiliary Power Outlet - Center Seat (AZ3) Auxiliary Power Outlet - Console (D07) Page 5480 - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Important: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service data wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Important: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. Page 7849 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J-38125-12A (12094429) into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 15482 Park Brake Cable Guide Replacement Removal Procedure 1. Release the park brake. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 3. Remove the park brake cable guide bolt from the frame. 4. Remove the park brake cable guide. 5. Remove the park brake cable guide from the park brake cable. Installation Procedure 1. Install the park brake cable guide to the park brake cable. 2. Install the park brake cable guide. Notice: Refer to Fastener Notice. 3. Install the park brake cable guide bolt to the frame. Tighten the bolt to 12 N.m (106 lb in). 4. Lower the vehicle. Page 14824 Page 6717 Refer to Splicing Copper Wire Using Splice Clips. See: Testing and Inspection/Component Tests and General Diagnostics Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Tools Required J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. See: Testing and Inspection/Component Tests and General Diagnostics You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. See: Testing and Inspection/Component Tests and General Diagnostics Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of Page 16173 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 5029 3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible. 4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator. 5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings. 6. Compress the handles until the ratchet automatically releases. 7. Place the terminal into the appropriate cavity and assemble the connector. Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro-Pack 100W) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure There are 2 styles of Micro-Pack 100W connectors. These connectors are very similar but use different terminals and have some minor physical differences also. Page 10096 17. Unsecure and position the EVAP canister vent solenoid clip (1) to the chassis EVAP line. 18. Install the EVAP canister vent solenoid pipe clip (2) from the chassis EVAP line. 19. If equipped with 4WD, install the fuel hose/pipe clip to the bracket on the transfer case. 20. Install the fuel line clip (1) to the bracket on the automatic transmission. Page 13775 6. Use the J 38125-213 or the J 38125-556 (GM P/N 12093647) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Important: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Bosch Connectors (0.64) Bosch Connectors (0.64) Page 6969 Page 2995 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 6870 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Notice: Refer to Test Probe Notice. Important: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Important: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. See: Testing and Inspection/Component Tests and General Diagnostics * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp Troubleshooting with a Test Lamp Tools Required J 35616-200 Test Light - Probe Kit Notice: Refer to Test Probe Notice. A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is Page 5322 9. Insert the J 38125-12A (GM P/N 12094429) tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 8087 present. In other words, if there is not enough current, the test lamp will not illuminage even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Using Connector Test Adapters Using Connector Test Adapters Notice: Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size. Using Fused Jumper Wires Using Fused Jumper Wires Tools Required J 36169-A Fused Jumper Wire Important: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/ECP Connectors AFL/EPC Connectors Tools Required J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement (Clamp In Style) Tire Pressure Indicator Sensor Replacement (Clamp In Style) Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove the tire/wheel assembly from the vehicle. Important: Before the tire is removed from the wheel, note the following items to avoid tire pressure sensor damage upon tire dismounting: * Place the sensors cap and valve on a dry clean surface after removal. The cap is aluminum and the valve is nickel plated to prevent corrosion and are not to be substituted with a cap or valve made of any other material. * When separating the tire bead from the wheel, position the bead breaking fixture 90 degrees from the valve stem. * Position the mounting/dismounting head so the tire iron, or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over the mounting/dismounting head. * Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the out side of the wheel rim. * Repeat items for inner bead. Remove the tire from the wheel. Important: If any tire sealant is noted upon tire dismounting, remove all residual liquid sealant from the inside of the tire and wheel surfaces. 3. Remove the tire pressure sensor nut. 4. Remove the tire pressure sensor. Installation Procedure 1. Clean any dirt or debris from the grommet sealing area. 2. Insert the sensor in the wheel hole with the air passage facing away from the wheel. Page 24168 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. Page 13012 View of the release tool being used for the smaller terminals. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Yazaki Connectors (2-Way) Yazaki Connectors (2-Way) Tools Required J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Disconnect the connector from the component.